Make Jid for cutting and wedding

This jid take us as long as a day to build, in few times , screw , unscrew..when we finally get it right .its beautiful.

Our hand is the most flexible manufacture tool so far!  Good to know our workshop machine can not do more than 45 degree angle directly.

 

Spot wedding is like another type of hot glue gun, but instead of melting plastic, it melt steel!

Thanks for the Jid , make wedding process easier! 20 mins Before the workshop close , we got the wedding done. The first testing steel frame is half done. Special thank you to Cam Holder, from another team:)

 

It look simple but never simple!

Another day of good team work!

Frame

Building a frame up is harder then we though. The frame we design have multi direction angles, the size to long or angle to wide to fit machine in the workshop.

Thanks the help from all kind tool, a deep drive in metal bending.

Options for body materials:

-recycled wire wrapped around the body
-canvas
-plastic
-fibreglass
-wood
-steel
-plastic chainmail
-silicone
-mdf

Requirements for body kit

The Body kit for our ebike must:

-be weather proof, to protect from moisture and wind
-streamline, to stop the wind from catching and reducing speed
-surface needs to be refined as to not injure people, or catch on clothes
-must be lightweight, to reduce any speed lagging
-must have enough strength to withhold minor crashes
-under body protection to shield electronics from environmental conditions
-opportunity for branding or logo to be placed
-aesthetically pleasing

Material Exploration

These images show different options for grip under the feet. As a lot of reliance is on your feet grip and the landing pad is very important.

Material Exploration

Body kit otions.

Paper Mache

Using paper mache we would be able to easily manipulate the shape and form of the body by paper mache-ing to a pattern. To reinforce the shape and strength wire would be necessary and the final pattern would then be dipped in resin for hardening.

Positives of a paper mache body kit:

-lightweight

-cheap? (depending on the resin)

-simple moulding process

-fast manufacturing

-reuse of waste material eg paper (sustainability)

-opportunity for users to make and replace their own body kit

Negatives:

-questionable strength
-durability
-structure

lean back concept design sketches (old)

New Design Concept

New Steering doodles

Steering Angle

Proportions