pic: Sheet Metal WCD

[androb4]

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[pmangels17]

Wow looks great. However, I have two suggestions. The top CIM looks like it could warp the plate backwards if it isn't thick enough. Also, I know personally that chain inside tubes is typically problematic, though not impossible. I would recommend all gears if going inside the rails, and even then, you need large access holes. A better alternative would be to let the chain be outside the rain, so you can tension it with ease and access it more easily.

[theawesome1730]

I would be concerned about warping or torquing the frame where the wheels are. We had some minor issues with using 2x1 inch 1/8 wall aluminum tube on our WCD this season, so just a precautionary

[GMAdan]

Great job!

Though I agree with the comments above. I would be worried about warping the frame as well especially sustains a strong impact. I would think about gusseting some of the corners as well as maybe adding a mounting point for the gearboxes on that cross beam. That way not all the load is just on that side plate.

just my 2cents

[BJT]

You might want to look into what it takes to put bumpers on a wcd.

[theawesome1730]

Originally Posted by BJT

You might want to look into what it takes to put bumpers on a wcd.

Oh yes. Bumper mounting was a pain this year. It can be done with tube and a welder, but it will be more challenging with sheet metal

[thefro526]

Originally Posted by theawesome1730

Oh yes. Bumper mounting was a pain this year. It can be done with tube and a welder, but it will be more challenging with sheet metal

On my previous team, we prototyped a 'sheet metal coast drive' in the off-season of 2011 and did sheet bumper mounts and they can be tricky. There is a bunch of information in this thread: http://www.chiefdelphi.com/forums/sh...ad.php?t=98808

[sdcantrell56]

Originally Posted by theawesome1730

I would be concerned about warping or torquing the frame where the wheels are. We had some minor issues with using 2x1 inch 1/8 wall aluminum tube on our WCD this season, so just a precautionary

I'm curious what type of issues you ran into with 2"x 1" tube. Was it 6061-T6?

[Akash Rastogi]

Originally Posted by thefro526

On my previous team, we prototyped a 'sheet metal coast drive' in the off-season of 2011 and did sheet bumper mounts and they can be tricky. There is a bunch of information in this thread: http://www.chiefdelphi.com/forums/sh...ad.php?t=98808

We designed some very simple .090" bumper mounting brackets on 3929 based off of 2826's. They have simple 90* bends to form two tabs on the sides to rivet or bolt through. https://sphotos-b.xx.fbcdn.net/hphot...81089086_n.jpg

That drive also used 2x1 tubing and had 0 issues with the chassis as far as I know. Bellypan was integrated .090" pan into the front and back cross member. 10/10 would build again.

Overall, I must admit I enjoyed designing with 2x1 tube much more than with a pure sheetmetal frame. I felt that it simplified the design and was easier to have parts manufactured with a mix of tube+sheet.