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May 16 2:52am PDT |
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Don't know what openCortex is? Learn about it. |
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Home » Projects » The John Lee |
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TEAM Yale College Solar Ra... |
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EVENTS attended Phaethon 2004 |
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USERS project members Burkhard, George Johnson, David |
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Link to... |
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+Article | +Photo |
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The John Lee djohnson http://solar.eng.yale.edu |
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| Related Content (9) | ||||
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| The John Lee Top Plug Photo by David Johnson created 8/15/2002 submitted 11/11/2002 12:37:18 PM This photo shows the top plug for Yale's 2003 ASC entry, The John Lee. This photo was taken after machining and before surface finishing. The plug was sanded to a smooth bare-foam finish, then any defects were filled using a short-hair fiberglass autobody filler. It was then painted with an epoxy primer-sealer. Following this coats of primer-surfacer were used and then wet-sanded off to create an automobile quality finish on the plug. Then the plug was sprayed with a final primer-sealer coat before waxing to prepare it for the molding process. | |
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| The John Lee Upper Shell Photo by David Johnson created 2/6/2002 submitted 2/7/2003 02:45:46 PM This shows the newly completed upper shell of The John Lee. Notice how the body sags slightly because it is not ribbed. You can see a crack running around the edge of the door. When this body is supported, this seam is not visible. The windscreen has not been added yet to the door. | |
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| Finished Bottom Plug Photo by David Johnson created 4/27/2003 submitted 4/28/2003 08:46:44 AM This shows the bottom plug immediately before the mold was made from it. The bottom plug was made by stacking foam in the same manner as the top plug. It was done in two halves as the CNC machine was not large enough to machine the entire vehicle at once. After both halves were machined they were joined together using epoxy and bolts. Following that the foam was sanded, primed, wet sanded, painted with black Imron, and then waxed. | |
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| The John Lee Top Mold Photo by David Johnson created 11/7/2002 submitted 11/11/2002 12:22:32 PM This photo shows the completed top mold of Yale's 2003 ASC entry, The John Lee. The mold was made by spraying chopper glass on top of a foam plug. The members in the picture are washing the PVA (a release agent used in the mold making) out of the mold to prepare it for layup. The mold is supported by a metal frame in order to provide support for the weak chopper glass mold. Metal was used rather than wood to allow for high temperature cures. | |
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| Detail View of The John Lee Foam Stack Photo by David Johnson created 7/12/2002 submitted 11/15/2002 07:37:36 PM This photo shows the foam stack for the top plug of The John Lee inside its crate shortly before shipping out for machining. The photo clearly shows the disadvantage of using epoxy for gluing foam blocks together. The low viscosity epoxy ran out from between the blocks and coated portions of the next layer of the foam stack. Ultimately this caused no problems in machining, but it wasted glue. | |
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| Team Lux Shipping Crate Photo by David Johnson created 7/10/2002 submitted 11/15/2002 07:22:33 PM This photo shows the structure of the shipping crate Team Lux used to send its stack of foam out to be CNCed into the top plug of The John Lee. The bottom of the crate was the torion box used to support the foam stack. The foam was glued directly to the bottom plywood skin. The top of the crate was covered with plywood to prevent damage during shipment. The crate (torion box and top) without foam weighed 1400lbs. Total shipping weight was 3600lbs. | |
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| JL Titanium Frame Photo by David Johnson created 6/21/2003 submitted 7/31/2003 06:29:32 PM This shows the titanium frame of The John Lee before it was permanently glued into the bottom shell. | |
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| Gluing Foam to Torsion Box Photo by David Johnson created 7/11/2002 submitted 11/15/2002 07:32:24 PM This photo shows the completed gluing of the first layer of foam for The John Lee top plug to our torsion box. The foam was donated to the team in 23.75" X 80.5" X 4" (+/- 0.25" in any dimension) blocks. The foam stack contained 7.5 blocks in the bottom layer (3 columns of 2.5 blocks each). Extreme care had to be taken to fit these blocks together so as not to leave gaps between the blocks that would cause voids in the machined plug. The photo shows the many heavy objects the team used to hold down the blocks during the epoxy cure. Epoxy resin was used to attach the blocks to the torsion box. It is not an ideal adhesive to attach foam to plywood due to its low viscosity and the absorption properties of the plywood. Thus significant amounts of adhesive were used on this first layer. | |
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| Adjusting Frame Position in Body Photo by David Johnson created 6/21/2003 submitted 7/31/2003 06:33:17 PM The position of the frame was aligned carefully with respect to the outer shell using a level and tape measures. We were able to position it to within 1mm of its CADed location by measuring diagonals to the edges of the body from all vertices of the frame. | |
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