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.