We’re looking to build a bomb proof chassis with 1x2 1/8". Most chassis examples we have seen don’t include gussets on the corners on the bottom, with the bellypan replacing them in function. Has anyone seen any problems with the corners of the chassis separating a little due to the holes in the bellypan enlarging or loosening?
Most people recommend 1/8 " polycarb or alum or 1/4" wood, The wood and the polycarb seem like they might crack or get deformed. Have you seen this? On our off season WCD with 1/4" luan plywood bellypan, the bottom coners of the frame separated a little with just the weight and torque of the gearboxes.
Would spacing the rivets 1/2" apart (instead of 1") be recommended in the corners of the bellypan? We’re not using versaframe.
Would a gusset sandwiching the bellypan and frame be silly?
We have always used bottom gussets and treated the extra stiffness that the belly pan adds as gravy. Ir you are looking for bomb proof that would be the way I would go. I can see using just the belly pan, but you would need to be sure that it ties together that chassis properly.
If the bellypan is a weaker material than the gussets you use on top, you could use corner gussets on the bottom that are like the ones on top, and cut the corners off the belly pan, to clear the gussets. No sandwich needed.
Never hurts.
We’ve built various versions of this the last 3 years. All the 2x1 are 1/8”. It has held up fine so far. There are lots of different ways to do the bumper rails depending on what the 2020 rules will be!
https://grabcad.com/library/team-4926-2019-off-season-drive-train-design-1
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