[JesseK]

Let's see if I can get this in under the radar...

As soon as our prototype frame was completed with all components assembled, I intentionally ran it 10 fps into the concrete wall of the high school with no bumpers. Other than a ding on the outer aluminum frame at the impact points, everything was ok. Then for the production frame, we rearranged some of the 1" aluminum extrusion to allow for an open front. Again, the same quality assurance test was completed, but this time at 12fps and testing was only done on frontal impacts. The result was a small dent in the front exposed tubing, but nothing severe like we had our first year.

During front impacts of the competition season, these aluminum bars became more and more crushed, which leads me to believe they served as a crush zone that made up for the lack of bumpers. In hindsight I'm glad we had them because that meant there was less shock force delivered to the rest of the components. While I don't condone running full speed at a wall to test your frame, I definitely think quality assurance tests are quite helpful. Plus they make for great videos...