Making a car door after the manufacturing the body


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Zeyad Gamal
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Hi guys, 

We are participating in the shell Eco marathon competition where we manufacture fuel efficient cars.

Due to rule changes for the 2019 season, we are now required to have a door on each side of the car. So we are now required to make a door on the other side of our current vehicle.

I was wondering if anyone has any suggestion on how we can cut the shape of the door and then put the part we cut back in its place and add a hinge to it ?

The main issue is that if we cut the door we will have a tiny gap when we put it back again, anyone got any idea how we can fix that ?

The body is made from carbon fiber and epoxy resin, manufactured by resin infusion technique.



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Furrari
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Hi. Looking at the overall car I think the small gap around any doors you add will be very small in comparison to other problem areas. If you are realy bothered about this, do the regs allow tape over the joints.

In my opinion the biggest Aero problem is the drag imposed by the large amount of clearance around the wheels, particularly the back. These areas need to be drastically tightened up with the wheels filling the wheel apperture. Further improvements in this area would be to add covers to both the inside and outside of the wheels.

The aero of the edges of the windscreen area could also be improved by adding a big a radius to the outside corners to promote a better boundary layer. This could further improved by adding a curved blade or vane, about 2” clear of the corner and slightly forwards to guide the air coming off the screen down the side of the car.

A small splitter on the front would also help by raising the pressure centre at the front, channelling the air over the top of the car rather than underneath. This splitter would ideally need to be 3/4” clear of the ground but I don’t know if conditions will allow this.

I can’t tell from the pics, but is the floor a continuous, flat surface as it needs to be as each change of surface will cause drag. A diffuser would also help as it would reduce/fill the vacuum left by the car behind it.

All this lot is easy to say but not so easy to do. Keep up the good work.

M
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Zeyad Gamal - 7 Years Ago
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