CalSol Bleeds Carbon Fiber

The last three weeks has seen a whirlwind of activity from CalSol as dozens of us have pushed even harder than before, toiling away mornings and nights to finish all of our carbon fiber layups. Too many nights have the clocks turned to 1am just to be back at 9am that same day, but we love seeing the massive push of progress. We just entered Spring break and those involved are taking a very well deserved rest for a day – just one – then back to work Monday!

CalSol, unidirectional carbon fiber, carbon fiber, unidirectional, solar car

Zephyr top shell, in our oven, mid-layup with the unidirectional carbon fiber adding stiffness to the structure

Zephyr is being built with a brand new manufacturing method for the team called pre-impregnated carbon fiber and Sam – shell lead – has been the champion of this process. He put in the hours to prep work and designs for the entire rest of the team to help implement. Long rolls of carbon fiber fabric impregnated with thermoset resin is laid out onto our smooth, waxed mold surface. Then CalSol members smooth and stick the fabric to the mold using heat and pressure making sure that there are zero wrinkles or air bubbles in the surface. This process is repeated with a smattering of nomex core, foam, and uni-directional carbon fiber in various areas all to increase the stiffness of the final product. Once satisfied, a release fabric is applied to the carbon fiber, then a cottony breather fabric, and lastly a large vacuum bag encases all of the carbon. Vacuum pumps suck the air out of the bag and press the carbon fiber into our smooth mold. Finally, we close the oven door and bake the carbon fiber to set the resin in place.

Quite a long process right? But now we are proud to say that we have finished all of the layups! We would also like to thank Patz Materials and Technologies for their help in making the pre-impregnated carbon fiber for us

Please enjoy the following photos that outline our thousands of man hours spent over the last 3 weeks.

CalSol, top shell, carbon fiber, solar car, layup

CalSol members having fun while working on the top shell of Zephyr

CalSol, solar car, support ribs, carbon fiber

Support ribs on Zephyr’s top shell to give added stiffness to the solar cells

CalSol, oven, top shell, carbon fiber

This photo was taken at about 1:30am as we pushed to finish the final few crucial steps to preparing the layup to be cooked inside of our oven

CalSol, Zephyr, top shell, pre-preg

We decided to throw a small party while unveiling the final top shell layup. This was our largest pre-preg layup to date and everyone was anxious to see what it would look like!

CalSol, Zephyr, pre-preg

The party was a great success and the top shell came out great! The surface finish is impeccable and the quality of the result is incredibly high.

CalSol, Zephyr, carbon fiber

Just last night we released Zephyr’s bottom shell from its mold and we ecstatic to see that it was just as perfect as the top shell!

 

 

 

 

 

 

Our Beautiful Composites

CalSol has progressed massively since our last shell team update! At our previous check in we had only finished one of our 8 fiberglass molds, completed zero carbon fiber layups, and we had a long way ahead of us. Now every mold has been finished, brought to a perfect shine, and 2 of the 8 parts of our car have been baked into flawless carbon fiber shells!!! You can’t imagine how happy and excited the team is that the body of our car is coming together!

solar car, sanding, fiberglass molds, shine

The sanding was just getting finished here on our top shell mold

fiberglass mold, bottom shell, solar car, composites

Holly, Jason, Pragaash, and Pol finishing bolting on the supports for our bottom shell fiberglass mold

 

pre-preg, carbon fiber, layup, composite

Aldrich standing by the pre-preg layup of our canopy for Zephyr

pre-preg, carbon fiber, composite

Our canopy as it came out of the mold, isn’t it beautiful??

pre-preg, carbon fiber, fairing, calsol, layup

Mandy and Sam holding up the rear fairing of Zephyr after some long nights of laying out the carbon fiber

 

 

 

 

Zephyr Chassis Complete!

Zephyr Chassis

Zephyr Chassis

We have finally completed Zephyr’s chassis, after a number of long months of design, testing, delays, and welding! Thank you to all of the different companies and people who have helped us throughout the design, verification, and fabrication process:

Garner Heat Treat – Test heat treatment for weld samples & actual chassis heat treatment

Dennis Lee & Michael Neufer – Tube bending, engineering advice, welding verification.

Maxal – Engineering advice and donation of 4943 Filler Rod

80/20 Inc – Donation of 80/20 chassis jig materials

Lotos Technology – Lotos TIG200 Welder – discount pricing

Jimmy Manos – Terminal Manufacturing Co. – Welding advice

UC Berkeley Etcheverry Student Machine Shop – Fabrication equipment and testing.

Tube Service Co. – Laser-cut aluminum tubes

Watch for more updates soon! We are getting lots of work done in these recent weeks.

After heat treatment

After heat treatment

 

 

 

First Fiberglass Mold

After many hours of working on our male plugs we are finally moving on to fiberglass mold construction. This week we were able to hammer out one of the fairings and it turned out GREAT!

fiberglass mold

 

Thanks to our new material sponsor, Aircraft Spruce and Specialty Co., we were able to acquire the fiberglass mat and mold making equipment required to build all the molds for Zephyr.

acsredblue

 

 

 

BBQ’ing at Work Sessions!

Every Saturday of every week about 15 or more team members find their way out to the Richmond Field Station working on the solar cars from dawn til dusk. Some members are welding, some sanding molds, some building our oven, some spraying, and some doing strategy calculations. But above all else, everyone is working tirelessly on making Zephyr become a reality. We are putting our heart, soul, and backs into this project and it will be an amazing sight to see drive once we finish it up.

But all that work is dreadfully tiring! You may say, “how do they work all that time without burning out?”. Well we found the solution: BBQ’ing!

chili, lime, shish kabobs, shish kabobs, chili lime, grill

Chili-Lime Shish Kabobs!

The first thing we tried was simple frozen hamburgers; we had to start slow and easy to build up our grilling chops.

Round two was Chili-Lime Shish Kabobs! These turned out incredible too. Marinated the chicken for an hour while we chopped up the vegetables and onions, assembled our creations, and 2.5 minutes on the grill for each of the 4 sides of the kabobs. Cooked to perfection.

Round three was a return to hamburgers but from scratch this time! Minced onions, teriyaki sauce, ground beef, a touch of flour, and other seasonings all mushed up together made the perfect patty. Grilled until fully cooked but still incredibly juicy so all the flavor stayed in. Remember, don’t squash your patties on the grill! It squishes all the juice out of them and you lose the flavor.

teriyaki, burger, cheeseburger, juicy burger, juicy hamburger

The most juicy teriyaki cheeseburger EVER

The food keeps us together and keeps us moving forward on our mission to build the greatest solar car CalSol has yet produced!

New Year, New Team: Gearing up for ASC 2014!

Greetings! We took a hiatus from blogging over the summer, but CalSol has been working hard over the last year to prepare for the American Solar Challenge 2014. As you will find out from our every-two-week posts, the team has acquired multitude of projects and talented members over the last few months who continue to turn Zephyr from a concept to reality.

CalSol @ RFS Tour

Composites Training @ RFS

HALLO~

In particular, the team was excited to find new details of the ASC 2014: it will start in Austin, Texas and end in St. Paul, Minnesota!

Exact locations of stage/checkpoints are still being finalized, but what we know for now:

  • Mon, July 21 (2014): Start in Austin, TX with a checkpoint in (TBD), TX
  • Tue, July 22: Arrive at stage stop in Norman, OK
  • Wed, July 23: Depart Norman, OK with a checkpoint in Wichita, KS
  • Thu, July 24: Arrive at stage stop in Overland Park, KS
  • Fri, July 25: Depart Overland Park, KS and arrive at stage stop in Omaha, NE
  • Sat, July 26: Depart Omaha, NE with a checkpoint in Ames, IA
  • Sun, July 27: Arrive at stage stop in La Crosse, WI
  • Mon, July 28: Finish in St. Paul/Minneapolis, MN

What we think the route might be:


View Larger Map

We are pretty stoked about this northbound driving across the central U.S! More updates to come from our other leads later.

Min Ju

Team Lead, CalSol