Surtes

The 2009 bodywork master was manufactured in-house by the team, directed by Ayman Saleh and Paul Morgan. The master was constructed out of layers of MDF. The panels were glued together using PVA glue and secured in place using 4” nails. The carbon fibre bodywork weighs about 3.9kg including the paint. The bodywork was moulded using carbon fibre pre-preg. It is assembled to the chassis using carbon fibre mounting brackets bonded to the chassis. Body panels are held together, and to the chassis, using riv-nuts that allow quick and easy removal of the bodywork for inspection and maintenance.

Process of bonding layers of the master together

Sanding down process to achieve a smooth profile

In order to check if the mould created by the team was good enough to be used for manufacturing the STAG 01 bodywork, it was decided to make an in-house glass fibre mockup bodywork. The same was done for the side panels. Once the dimensions of the moulds were checked and signed off by our team leader Timothy Bingham, it was send to Carbon-mods for manufacturing the carbon fibre bodywork. The finished product was received on the 15th of April 2009.

Process of fabricating preliminary glass fibre cast and geometry checks

Side Pod Fabrication Components

Final SURTES 2009 Fabricated, Fastened and Painted Bodywork Design

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	Bodywork development The 2009 bodywork master was manufactured in-house by the team, directed by Ayman Saleh and Paul Morgan. The master was constructed out of layers of MDF. The panels were glued together using PVA glue and secured in place using 4” nails. The carbon fibre bodywork weighs about 3.9kg including the paint. The bodywork was moulded using carbon fibre pre-preg. It is assembled to the chassis using carbon fibre mounting brackets bonded to the chassis. Body panels are held together, and to the chassis, using riv-nuts that allow quick and easy removal of the bodywork for inspection and maintenance. Process of bonding layers of the master together Sanding down process to achieve a smooth profile In order to check if the mould created by the team was good enough to be used for manufacturing the STAG 01 bodywork, it was decided to make an in-house glass fibre mockup bodywork. The same was done for the side panels. Once the dimensions of the moulds were checked and signed off by our team leader Timothy Bingham, it was send to Carbon-mods for manufacturing the carbon fibre bodywork. The finished product was received on the 15th of April 2009. Process of fabricating preliminary glass fibre cast and geometry checks Side Pod Fabrication Components Final SURTES 2009 Fabricated, Fastened and Painted Bodywork Design Back	v