Duke University Motorsports is a student group that designs and builds open wheel, single seat race cars to compete in the Formula SAE competition sponsored by the Society of Automotive Engineers. The team consists of Duke students from both Pratt and Trinity, in all classes. The purpose of the team is to provide students with a way to gain practical design and manufacturing experience in a fun and challenging setting.

Friday, February 3, 2012

Making the fuel tank, part 1

We make our fuel tank out of sheet aluminum.  We design it in solidworks, cut out each of the pieces, bend the pieces where appropriate, and then weld everything together.  The main fuel tank box looks something like this:
Partially welded fuel tank main box

We will then attach the filler neck, pickup box, and attach the fittings.  On the filler neck, we have to weld on fittings for the sight line and the fuel cap bung.  On the fuel pickup box, we have to weld in a fitting for the fuel pickup.

The end plates are CNC'd, and the top, bottom, front and back are cut on the bandsaw and bent in the student shop.

This is the first real part I've welded in aluminum.  Not too hard, and once I got comfortable I was able to go very quickly.

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