Design of the Human Powered Vehicle:
The design of the Human Powered Vehicle is split into many steps and phases. The first phase (the planning and trouble shooting phase) took nearly 4 months over the summer just planning, drawing, problem solving, etc., on the ideas and concepts of the team members.
After considering all of the constraints (ie: maximum points that the monocoque fairing must loft over) and deciding on an aerodynamic design for the fairing, the next step is to construct it. The basic steps to constructing a monocoque fairing are as follows:
Build Strongback
Construct Plug
Construct Mold
Create Shell
Designing the Strongback:
The strongback is the backbone of the entire plug. This must be strong, rigid, and true, if one wants good results.
Constructing the Plug:
The plug is comprised of foam blocks, Bondo, and plywood, shaped and cut into an aerodynamic shape.
Constructing the Mold
The mold is a fiberglass shell made from the plug.
Creating the Shell
The shell is a composite inlay of the fiberglass mold.