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We're back from Alabama, and we're pleased to say that our first competition this season was a great success. Most notably we placed 1st in Suspension and Traction, and 7th in the competition overall.

This competition started out very wet, with a cyclone warning and a torrential downpour during design judging. As such, the course was extremely muddy, so much so that we had to shovel mud off of the car at pit stops.

A few kinks quickly worked themselves out on the practice track, one CV boot ate itself, our RPM sensing disk catastrophically collided with it's sensor. Once the CVT cover was off, it was very clear why the engine had stalled!

The endurance race was driven very well by Brett, who managed to avoid the fate of some less fortunate cars who rolled, turned turtle in the water, and caught on fire!

Our car was extremely reliable on the endurance course, with no broken parts, which was our biggest goal and something very hard to achieve. We would like to thank all of our sponsors that made this possible, and also to the teams that helped us out with things such as late night motel welding, CV boots, work lights, compressed air and miscellaneous hardware "borrowing".

To see more photos, checkout the photoset here: http://farm6.static.flickr.com/5182/5639837066_a7047171c1.jpg

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Our CVT backing plate was manufactured using SPIF (Single Point Incremental Forming). SPIF is carried out by a mill that moves around with a dull point and stretches a sheet of aluminum a little bit at a time. Because the process happens in a mill, finish machining operations are easy to carry out, as the part is already located.

CVT Backing Plate - SPIF from Queen's Baja on Vimeo.

Machine Operator: Dave Adams

Filming and video editing: Simon Winter

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This year's gear "box" (flaps open for clarity) :

Incase your wondering, we've done the FEA, cardboard should hold up fine.

 

The real deal, and a rapid prototyped 1/2 scale model of our 5:1 planetary gearbox.

 

Meet our newest team member- Mr. Gearhead

 

Here you can see a closeup of our spider that supports one side of the planet pins. We did this on a stiffer and faster machine, so Dave was able to crank up the feed and speed, and did the bearing fit in one shot with an end-mill instead of a boring head.

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