The rules for the Cannonball ZEV International Runs are simple, you must use production vehicle running gear - and the car must be road legal. The ultimate prize is the Blue Bird World Cup. Check out the construction sequence below as a guide to building (converting) your own Cannonballer. This unique car began life as an Austin-Rover Metro. The team say that it would not be hard for them to produce chassis kits for others to build their own electric city car from a donor car. They might though choose from current production models for donor running gear.
[Left] This is an example of a superbly penetrating weld using a MIG machine. The steel being joined was 3mm angle iron to 2.5mm subframe. A very ancient SIP 150 was used that had seen better days and caused many problems that needed to be rectified before welding could begin. This was hardly surprising given the 30 year age of the equipment. In that not much welding was required, the team elected not to rent gas cylinders from BOC or Air Products. Instead, they used small disposable bottles that can be purchased from Halfords, Tool Station, Clarke or Ebay. This way you only purchase what you need and don't have the bother of masses of paperwork. [Right] This is an example of a weld using high nickel content rods and an Oxford Bantam that is now 40 years old and still going strong.
The de Haviland Mosquito WWII bomber, is another aircraft built of wood to reduce weight. The oval-section fuselage of this craft was a frameless monocoque shell built in two halves being formed to shape by band clamps over a mahogany mould, each holding one half of the fuselage, split vertically. The shell halves were made of sheets of Ecuadorean balsawood sandwiched between sheets of Canadian birch, but in areas needing extra strength— such as along cut-outs— stronger woods replaced the balsa filler; the overall thickness of the birch and balsa sandwich skin was only 7⁄16 inch (11 mm). This sandwich skin was so stiff that no internal reinforcement was necessary from the wing's rear spar to the tail bearing bulkhead. The all-wood wing was built as a one-piece structure. It was made up of two main spars, spruce and plywood compression ribs, stringers, and a plywood covering. The outer plywood skin was covered and doped as was the fuselage.
Terry (project co-founder) cutting a chassis rail to length using a soft-start 9" Xpert angle grinder. Note that he is wearing safety glasses but not overalls. It was though a very hot day in August 2014.
Making the gull-wing door hinges in steel - jigged for welding - June 2014. The solar powered shield is especially useful, leaving both hands free. The lens in this mask automatically darkens to prevent eye damage as soon as you strike a spark. Brilliant!
And here it is in action. This superb photograph (edited down to a lower quality for the web) of the second set of hinges being welded for the DC50s gull wing doors, was taken by the team's archivist on the 28th August of 2014 © Karl Lindsay Photography. The welder is reasonably hardened, such that he does not wear gloves for short duration fabrication and seemed immune to spatter. You would be well advised to wear gauntlet type gloves if welding a lot and especially when positional welding upside down, when you will get white hot balls of steel raining down on you. Ouch!
the home chassis builder, disposable gas cylinders are a blessing. Some decent
gas combinations are now available is the standard 1 liter size. There is even a
portable gas brazing & welding kit for around £138 that lets hobbyists obtain professional quality welding.
The kit is ideal for plumbing, air conditioning and refrigerating system repairs. Each Set of Cylinders
should give approx 30 minutes of continuous use. The disposable cylinder system
reduces overheads for small enterprises.
face shield & instructions.
ECOSTAR DC50 EV CHASSIS FEATURES
ECOSTAR DC50 LINKS A-Z
AERODYNAMIC BODYWORK CONTROL SURFACES
BODYWORK ALLOY & COMPOSITES - BOOT
COMPETITION: BETTER PLACE - TESLA
COMPETITON: SUZUKI ALTO & NISSAN LEAF
MECHANICS, SUSPENSION, STEERING, BRAKES
SERVICES STATION INFRASTRUCTURE
SLEP - SOUTH EAST LOCAL ENTERPRISE PARTNERS
H beam Welding Production Line
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