The end of the week

This week we successfully finished our presentations and had time to accomplish our chores.  We were able to dust the trophy case, clean up the general area, clean some more metal, and worked on trying to fix the welder.
When it came to cleaning metal, the pieces would begin to rust again after a few days, so we sprayed them down with WD-40 to prevent that from happening.

Peter sprays metal pieces down with WD-40.

Matt sands down wood for his project.

Solar Presentations

This week we will make the revisions to our presentations.  The final drafts will be due on Wednesday.  After we turn in our blogs we will have to finish a number of chores to make the work area cleaner. 
As of now, my presentation is okay.  All I need to do is add a couple of graphics and a slide on wattage, amperage v. voltage, and an example slide on the ohms formula.

Jack cleans metal

Jaret cleans up SK3 area

Tuesday Blog

Today is the last blog before Thanksgiving break.  Today we are still working on our presentations and we also have a special assignment to fix a trampoline.  We will need to put a new weld on it to fix it.

Fixing the trampoline.

Getting ready to weld the trampoline.

Monday Blog

This week is only two days so the blogs will be short and simple. Today, we have to unload SK3 and remove the top.  We also have to finish up our powerpoint presentations.  The rough drafts are do tomorrow and they will be counted as our midterms.

Zach works diligently on his presentation.

SK3 put perfectly back into place.

It's a Parade.

This week we accomplished our goals of cleaning at least half the metal pieces and we also replaced the brake pads on SK3.  The battery rack is almost done.  The holes have all been drilled in the steel pieces and now we just need to put them all together.  We may have broken a few bits drilling, but it was well worth it.
This week was also the week leading up to the Holiday Parade.  Since Solar Knights is part of the parade, we helped by loading SK3 on to the flatbed trailer on Matt's car.

Battery rack almost complete.

Jasen steers SK3 onto the flatbed.

Cleaning metal time

This week our plan is to continue cleaning the metal pieces so they can be ready or welding.  Jack and Zach are working on building the battery rack for SK2, and the brake pads are being replaced on SK3.  We have found that if the cleaned metal pieces are left out for too long they begin to rust again, so Matt suggests we use WD-40 to prevent that from happening.  Our goals for this week are . . .

A) Clean at least half of the metal

B) Finish replacing the brakes

C) Finish the battery rack

Zach cleans metal with the wire wheel.

Zach prepares to drill down pieces of the battery rack.

It's Welding Time!

This week we were able to cut up about 3/4 of the birdcage and clean a lot more of the parts.  We put on a second wire wheel so we could clean twice as much pieces.  On Friday we were finally far along enough on cutting and cleaning that we started welding.  We learned about the right angle to weld at and the slow circular motions necessary to create a clean weld.

We were also able to make progress on our presentations.  I would say that the majority of us are at least halfway done with the presentations.

Matt welds pieces of the birdcage together.

Matt uses the angle grinder to smooth out the weld.

First week with the plan

This week we plan on implementing our new schedule.  Hopefully, we will be able to divide and conquer in working on the welding project, our power point presentations and the solar car.  Our goals this week are to . . .

a) cut up most of the birdcage

b) clean more pieces

c) make progress on our presentation

d) start welding

Jaret and Peter finish off a section of the birdcage.

Jaret cuts off rods of the birdcage.

Super Solar Schedule!

On Wednesday this week we all sat down and decided on a weekly schedule to follow for the rest of the year.  We decided that no one wanted to do nothing but clean for a week, and then do nothing but metal works for another week.  Our new schedule allows us to do a little of everything each week.
Our new schedule is . . .

Monday-Metal works
Tuesday-Clean/Computer
Wednesday-Metal works
Thursday-Solar car
Friday-Clean/Computer

Another part of our decision was to start creating tutorials so that we can teach one another about the different technical aspects of engineering.  We also need to create a small multiple choice test to go along with each tutorial.

Mike works on his tutorial.

Peter sweeps on our first cleaning Friday.

Sweeping and Cleaning and Cutting! Oh My!

This week, we plan on cutting up the birdcage and preparing the metal pieces so we can work on our welding project.  We also want to clean our work area.  There is a lot of dust and shavings from the machines, so we will sweep the floors and machines clean.  Our goals this week our to . . .

A) Clean up the work area

B) Clean metal pieces and cut more pieces off the birdcage

C) Finish battery mount for solar car

Kirsten cleans off metal pieces with a wire wheel

Jack cuts up aluminum with an angle
 grinder for the battery mount

Sorting Complete

This week we were successfully able to reorganize all tools and hardware.  Hopefully, our new organization of things will make completing projects faster and more efficient.  Next week, we plan on putting the final touches by making labels for all bins and tool chest drawers.  We also plan on continuing our welding projects by cutting up the bird cage and using the wire wheel to clean the pieces.

Separating standard and metric drivers.

Organizing metric wrenches by size.

Solar Sorting

Last week we received brand new tools as well as new bins, tool boxes, and a label maker.  Before we can break in the new tools and continue our projects, we must reorganize all our tools and hardware.  Right now we have all our bolts, nuts, and washers all mixed together in large buckets and and all of our tools are mixed together in the tool chests.  Metric wrenches and with standard wrenches and Phillip's head screwdrivers are with Flathead screwdrivers.  We must stop the madness.

Our goals for this week are . . .

A) separating the bolts, washers, and nuts by size

B) reorganizing the tool chests

C) reorganizing the tool cabinet

Kirsten dumps out screwdrivers from a tool chest drawer so
we can separate the Phillips from the Flatheads.

I separate bolts by size and thread in this box.

Solar Santa Came Early This Year!

This week we were able to cut up the bottom out of the birdcage and about 1/8 of the body.  We were also able to start cleaning off some of the pieces with a wire wheel.  Jaret's dad even taught us how to weld properly.  We did not get a chance to cut the pieces for the battery mount; we will do that next week or the week after.

We also received a lot of new tools this week including welding masks with transitions lenses and a label maker.  We also got new drills and an air compressor.

New tools!!!

Kirsten attempts to use the angle grinder.

Battery Mount and Metal Works

This week we need to continue working on the two rear battery mounts, we have the aluminum ready to be cut to make the mounts but because it is thick aluminum and to be practical we need to cut it with the angle grinder.

Furthermore a lot of us are being taught how to weld, because it is a crucial skill to building with metal.  Jaret's dad has come in to teach us how to properly use an angle grinder, so that we can cut up the metal we need for welding.  We received a birdcage that we will use as scrap metal.  Our goals this week are to . . .

A) Learn to angle grind

B) Start cutting up the bidcage

C) Get metal pieces for battery mount

Jaret's dad teaches us to angle grind.

Location for the two battery mounting brackets

We Weld Well

This week we successfully mounted the electric motor to SK2 and we changed the suspension as well.  Afterwords, we even began trying to attach the motor to the back wheels rotor with a chain.  At the current moment, we cannot find a chain of proper length, so we will continue our search next week.  We did get around to threading the holes for the tie bars.  Matt needs to take the bolts we found to home depot to find their exact size.  That way we can make an accurate thread.

We also got a special treat this week, we learned how to weld.  Each one of us got to practice welding bolts together.  We learned that the arc created from welding is bright enough to cause you to go blind, so we took special precaution by averting our eyes and wearing welder masks that block out the light.  It was great to be able to learn this new skill.

Matt demonstrates proper welding techniques.

Jaret looks for a chain of proper length for the motor.

Everything's Coming Up Solar

At this point we have sent away our list for the parts we need, and we will be getting them soon.  In the mean time, we plan on attaching all the other parts on SK2 that we can that don't involve the parts we are waiting for.  With that said, are goals this week are . . .

a) changing the suspension

b) placing the motor

c) placing the tie bars

We will have to find the necessary bolts to attach the motor, and we will have to thread the hole to be able to bolt in the tie bars on SK2.  The current suspension is very weak, but changing it should not be a problem.  After the motor is mounted, we will connect it to the back wheel motor with a chain.  If all goes well, all that will be left is to fix the steering, putting on the tires, and wiring the controllers.

Jaret and Jack placing the motor on SK2

Zach and Jack changing the suspension on SK2

Powerless without power tools

This week Mr. Martin was out of class for a couple days so we were not able to use any power tools.  The tie bars were not able to be put on because of that and we made little progress on the battery brackets.  We did, however, manage to put on the seat to SK2 and we decided to create the connection wires for the batteries.  All we needed was a hammer and some clamps for that one.  Hopefully, we will be able to attach the tie bars early next week.

Matt teaches us to spool steel wire for welding

Peter cuts wire for the battery connections

Body and Framework

This week we need to start focusing on the frame of SK2 because if not were going to be held up in the future. So we are going to remove the lone supporting bar on the left of the drivers seat that is no use to the car or driver. Furthermore we must refine the supports around and behind the driver while adding in 2 battery mounting brackets behind the driver. to do this we will be using long aluminum 1/4" bars and cutting them into defined pieces for the bracket. The weeks goals include . . .

a) putting on the tie bars

b) putting on the seat

c) building the mounting brackets

Jaret tests out the seat on SK2

Jack is sawing leftover aluminum for the mounting brackets

At Long Last, Fully Mounted

This week we were able to fully mount the motor controller and charge controller.  After locating the necessary hardware Kirsten and I began to bolt the two controllers down.  In some areas the bolts could not be properly fastened because the holes in the aluminum were too big to screw on the nuts.  We were able to use washers to fasten the nuts.  We then used spring washers after the first washer on all the bolts because if we were to hit a bad bump in SK2, there would be a lower chance that the bolt would snap.

After everything was bolted down, Matt suggested that we cut the bolts down to a smaller size.  He said that if we hit a bump in SK2, the back end of the car bounce low enough to have the bolts puncture the back wheel.  We then cut and filed all the bolts, and then mounted the controllers.

Jack was able to design a rack for the batteries to be placed and has begun gathering his materials.  I have begun researching how to wire our electric motor to the controllers.  Our motor is a pancake dc motor made by Heinzmann company.  We have not yet installed the potentiometer but Jaret is looking into how to wire it.  Hopefully next week we can install the potentiometer, the battery rack, and possibly even the tires.

Serial information on the electric motor.

Bolting the motor and charge controllers down with Kirsten.

Battery Brainstorm

This week we will be planning on a new design for where the batteries for SK2 will be placed.  Originally, the batteries where all located in the front compartment, but we are realizing the problems with this design.  With all weight in the front, with no suspension, hitting a bump or pothole will damage SK2.  Instead, we are going to decrease the amount of batteries used from six to four, and only have two in the front.  The other two will be placed behind the driver's seat, in a rack that we will design later.  That way most of the weight will be placed in the center of the vehicle.

In other news, we are also working to get a solar go-kart in operation as a side project.  Are goals this week include . . .

Mounting charge and motor controllers

Designing new battery rack

Installing potentiometer

Matt leads the brainstorm on where to relocate the batteries on SK2

Checking out the go-kart and where the batteries,
motor controller, charge controller, etc. need to be placed

Setting Better Solar Goals

This week we were not able to finish mounting the charge and motor controller.  Our progress is slow so on Wednesday we decided as a group that it is important that we all focus on being more efficient.  Everyone is to have some sort of job everyday that they can work on and we will begin to set more concrete weekly goals.  Our first new goal is to get SK2 rolling by the end of next week.

In other news, we took off the wheels on SK2 so that we can remove the inner tubes from them.  The SK2 will be able to go faster without them, and they are not essential to SK2's operation.

At the end of the week we had a friendly competition! We split up into three groups and tried to see which group could build a set of rolling shelves the fastest.  The winner is still debatable at this point so I would say Matt, PJ, and Jason won.

Using screwdrivers as leverage to remove the tires from their respective wheels

Using brute force to remove the tires from their respective wheels while Matt supervises.

Leave no SK behind

This week we are focusing more of our attention to SK2 by mounting the Outback and motor controllers.  The controllers will be one of the first piece of hardware added to the actual frame.  After they are mounted we will be able to add other pieces to SK2, such as the motor and steering aparatus.  With that said, we plan to get SK2 rolling by next friday. It is a tall order but we are confident that we can do it. 

 On the other hand we are also waiting the new bearings for SK3's wheels.  Our overall goals this week are . . .

a) Find the hardware to mount controllers

b) drill the holes for the controllers

c) mount the controllers

Peter Drilling holes in SK2 for the motor controller

Zach looks for the right bolts to mount the motor controller and charge controllers

Tie Bars and Brake Lines, Oh My!

This week we cleaned the brake system on SK3 until they were spotless.  We were also successful on researching new brake lines for SK3, but according to Matt and Mr. Martin, we are waiting for money from the county before we continue.
The tie bars for SK2 were too small, so next week we will have to look again for ones that fit.  We also decided where to place the Outback and motor controller and have begun drilling.
This week everyone learned about soldering wires together from Jaret, which is an important skill when it comes to repairing motors.

Cleaning brake pads with degreaser and microfibers



Jaret teaches us how to solder wires together

Getting Down to Solar Business

This week we plan on continuing the construction of SK2.  We also need to continue cleaning the brake system for SK3.  The details of our plans include . . .

a) Placing the charge controller and motor controller on SK2,

b) Cleaning the brake pads on SK3,

c) Researching new brake lines for SK3,

d) Placing the tie bars on SK2.

Our Monday meeting going over the plans for the week.



Me and Jack researching HOPE C2 brake lines

Both front wheels have been disassembled on SK3 and the process of rigorously cleaning is almost done, if we leave any dirt or grime it could lead the way to rust and or degrading of the brake's.

Jack Cleaning the last of the brake/brake pad's

Cleaning SK3

Since SK3 is the main competition solar car, it takes a lot of work to keep it up to standard. This week we need to take of the wheels and completely clean the axle and bearings of brake fluid that had leaked out during competition.

The First Axle ready for cleaning