11/10/06

How we build our vehicles

 •         A mild steel, MIG welded prototype chassis is built, mostly by students, for any significantly new vehicle.

•         Jigs are used for chassis and front axle assemblies to simplify process.

•         Technology teacher, John Taylor, is the chief ‘project manager’.

•         Students at least assist in nearly all aspects of vehicle construction.  

                                                 Braze welding a prototype chassis in jig.

•         Parents, teachers and professionals assist with some construction tasks, eg. aluminium welding.

•         Cro-Mo race chassis is usually tack welded by students with final welding performed by a professional welder, either MIG or TIG.

•         Canopy moulds are made by John Taylor with some parent and student assistance.

•         Students and parents assist with canopy ‘lay-up’ and repairs.

•         Parents and/or professionals perform all painting.                                        PJ2 prototype.

•         Many parts, eg. canopy latches,  tail-lights and wiring looms, are made entirely by students.              

•         We have built at least one new vehicle each year since we started in 1999.

      Making large chain wheels                                      Fitting chassis to canopy