pic: WCD Sheet Metal Hybrid

[AdamHeard]

Originally Posted by Greg Woelki

Thanks for the supplier. I downloaded the STEP file and it is 0.0625" wall.

Since you're in MA, I doubt they would shop that for (nor would it be logical).

However, I'm certain there is someone filling an equivalent role out there. Figure out where machine shops buy their aluminum and ask them.

[KrazyCarl92]

Originally Posted by AdamHeard

Since you're in MA, I doubt they would shop that for (nor would it be logical).

However, I'm certain there is someone filling an equivalent role out there. Figure out where machine shops buy their aluminum and ask them.

We inquired about an order through Coast Aluminum last year for that material specifically and it didn't work out because shipping to New York was prohibitive for them. However, we were able to find 0.080" wall 2 x 1 6061 aluminum rectangular tube through Alro Metals. It arrived with a kink in the middle, likely from shipping, but we were able to use the material on either side of the kink anyway with little waste. We used this for our rear rail and bumper supports on our WCD. We used 0.125" wall on our front rail due to concerns about the stresses on the frame in that area from our 4 large torsion springs, but I would venture to say we would use 0.080" on that front rail in most years moving forward.

[Akash Rastogi]

Originally Posted by KrazyCarl92

We inquired about an order through Coast Aluminum last year for that material specifically and it didn't work out because shipping to New York was prohibitive for them. However, we were able to find 0.080" wall 2 x 1 6061 aluminum rectangular tube through Alro Metals. It arrived with a kink in the middle, likely from shipping, but we were able to use the material on either side of the kink anyway with little waste. We used this for our rear rail and bumper supports on our WCD. We used 0.125" wall on our front rail due to concerns about the stresses on the frame in that area from our 4 large torsion springs, but I would venture to say we would use 0.080" on that front rail in most years moving forward.

I looked into Alro a while ago for .062" wall, and they had it. 1251 showed it to me as I think it's still where they order from.

Check out page 10-52 http://www.alro.com/datacatalog/010-...um.pdf#Page=52

[roystur44]

Cory,

How about slotting the top of the 1 x 2 tubes so the bearing blocks drop in from the top. Once tighten the bearing block becomes integral to the frame and strengthens the tube. That would make your transmissions and wheels drop right in.

Using 6061 T-6 for your belly pan would be fine if then is no bends. Laser away.

There is a process called bump bending in which a series of small tangent bends along a radius which used to create a large radius bend in sheet metal. You can use that process to bend T6. T6 Sheet stock just requires a large inner radius or use of a wrapper while bending.

If you are worried about your front/back bending in you could attach a small hat section of sheet metal behind the front and back along the length. This also could serve to be the mounting rail for the manipulator. I think being able to mount and adjust the manipulator is very important in a design.

Here's another idea. How about making the front and back circular?



You have a good start.

[rcmolloy]

Hey Roy thanks for the reply. Sorry it took me a bit longer to get back to you. The 4th was a bit in the way this past weekend!

How about slotting the top of the 1 x 2 tubes so the bearing blocks drop in from the top. Once tighten the bearing block becomes integral to the frame and strengthens the tube. That would make your transmissions and wheels drop right in.

Hmm, didn't think about this. It's surely possible and I'll definitely toy with the idea. It would be nice to have all components "assembled" with chain and then drop right in like you mention.

Using 6061 T-6 for your belly pan would be fine if then is no bends. Laser away.

There is a process called bump bending in which a series of small tangent bends along a radius which used to create a large radius bend in sheet metal. You can use that process to bend T6. T6 Sheet stock just requires a large inner radius or use of a wrapper while bending.

This was super surprising since I didn't know that there was a method of doing so available. I would have figured a larger radius would be needed but that its characterized as bumping is certainly not jargon I know. Surprisingly, now that I think of it, I'm pretty certain I have seen this used in some applications. I didn't really think of it until now.

If you are worried about your front/back bending in you could attach a small hat section of sheet metal behind the front and back along the length. This also could serve to be the mounting rail for the manipulator. I think being able to mount and adjust the manipulator is very important in a design.

I certainly have thought about this and I do think this will be added in the near future. I just need to sit down with this guy for a bit longer until it should be solid for competitive purposes with the likelyhood of no plastic deformation.

Here's another idea. How about making the front and back circular?

Funny thing is I have been looking at doing a similar design as 971 has been doing for the past 2 years (correct me if I'm wrong) but I haven't dove into that yet since the kids are looking to do something during the off-season. They've already made headway and I'll most likely design after due to seeing flaws with it.

Thanks for all the help!