Chassis

From Trevipedia

Trev is built around a structural tub chassis fabricated from composite sandwich panels. Low-mass non-structural body panels are fitted to the tub to form an aesthetic and aerodynamic body.

The technique used to build the UniSA prototype is summarised in three articles in AutoSpeed magazine:

• Building an Ultra Light-Weight Car, Part 1
• Building an Ultra Light-Weight Car, Part 2
• Custom Bubble Canopies

The construction technique is simple and effective.

The image below shows the layout of the UniSA prototype tub.

More details can be seen in the SketchUp model Tub_1.skp. The original CAD model, containing the body and tub chassis, is available as a UniGraphics model or as a DXF conversion.

There are several changes to the design that should be considered:

• Can we use floor boards with stronger, stiffer skin so that we do not need to wrap the floor in Kevlar?

• Can we fit the battery into the floor instead of in the front, so it is better protected? This would raise the height of the rest of the car, but it would also provide space for running electrical cables, brake lines and the handbrake cable.

• Longer front wishbones

• Fitting the motor and transmission completely outside the tub would make it much easier to install.

• Side intrusion beams should be folded into the doors.

SketchUp model Tub_2.skp shows an example tub with a improved rear seat, simpler rear side panels, and the motor outside the tub. This version also incorporates some of the Team Trev modifications:

• The battery box beneath the car allows a range of lithium ion polymer cells, up to 13 kWh (260 km range), and contains the entire high voltage system. The battery box is narrower at the front to allow longer lower wishbones to be mounted under the main floor.

• Vectrix rear end.