Assembly line covering the firewalls and floor panels from CR25 onward.
Groups the main hoop firewall, seat firewall, engine firewall and floor panels into one costed assembly. Design Philosophies and Processes: Inherited from the Body Work and Nose subsystem design process: 1. Take the outer surface from the aerodynamics CFD geometry so the panel is the same surface that was simulated. 2. Choose a laminate schedule using the team's laminate weight calculator, trading ply count against stiffness and surface finish. 3. Mold: tooling board milled on the 5-axis gantry for large surfaces, 3D printed molds for small parts. Automotive clearcoat over the print cut roughly 22 hours of sanding and made the molds reusable. 4. Layup and cure, then post-process, fill the leading edges with polyester filler and satin clearcoat for UV protection. 5. Test fit on the frame, then trim and drill mounting hardware to jigs.
CR22 layup schedules, from the composites manufacturing pages. Layers are listed surface layer first, inner layer last. Driver firewall: 1. 0-90 Textreme (76 gsm) 2. +-45 stitched construction ply (150 gsm) 3. 0-90 stitched construction ply (240 gsm) 4. Nomex honeycomb core (0.25 in) 5. 0-90 stitched construction ply (240 gsm) 6. +-45 stitched construction ply (150 gsm) 7. 0-90 Textreme (76 gsm) Engine firewall: 1. 0-90 Textreme (76 gsm) 2. +-45 stitched construction ply (150 gsm) 3. +-45 stitched construction ply (150 gsm) 4. 0-90 Textreme (76 gsm) The driver firewall is a cored sandwich panel and the engine firewall is a thin solid laminate, which is the whole difference between them. The floor and body panel sections of the same page are headings with nothing under them, so no floor panel schedule is recorded for CR22.
From the CR22 composites layup schedules. This is the laminate, not a full bill of materials: no adhesive, core splice, insert or fastener quantities are recorded on that page. - 0-90 Textreme, 76 gsm. Driver firewall: 2 plies. Engine firewall: 2 plies. - +-45 stitched construction ply, 150 gsm. Driver firewall: 2 plies. Engine firewall: 2 plies. - 0-90 stitched construction ply, 240 gsm. Driver firewall only: 2 plies, one either side of the core. - Nomex honeycomb core, 0.25 in. Driver firewall only.
None recorded. This part has no entry in Knowledge_Transfer/Issue Logging/Fault Vault.xlsx, in either Issue Log.xlsx, in CR22/Issue Tracking/Shakedown 7-15-23.xlsx, or in any design review issue list found in CrimsonStorage or Box.
Nothing in CrimsonStorage covers these yet.