HHS Scratch-build Custom Greenpower F24

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HHS Greenpower
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HHS Scratch-build Custom Greenpower F24

Post by HHS Greenpower » Mon Nov 06, 2017 8:43 pm

The Huntsville High School Greenpower Racing Team in Huntsville, AL has taken on a built from scratch student-designed race car utilizing the stitch and glue fabrication and 3mm Okoume plywood. Our team competes in the GreenpowerUSA Stem-based program along with over 250 other teams in the USA. For reference, please visit GreenpowerUSA.net. Our team decided that for our second year, we would take on building a scratch-built custom car. This thread depicts our process. We started the design process back in June of 2017 and have progressed through two prototypes and as of today November 6, 2017 we started the final assembly. We welcome any questions and look forward to more team taking on this approach to the custom class of Greenpower.

The team set out with a few goals: 1) build a custom car with high school student design/fabrication capabilities, 2) build a car that weight less than 100 lbs without driver and batteries, 3) compete to win!

Our high school does not a fabrication shop on campus. We have been provided a typical classroom to use as our garage shop. We started our project by researching what the easiest custom car fabrication would be. As the Greenpower program started some 19 years ago in the UK, we looked to their experience. We found a project with great documentation and guidelines to help us through the process. Their design can be found at: greenpowereasybuild.blogspot.com. From here, we built a cardboard prototype to "concept" the build.
Cardboard Prototype
Cardboard Prototype
Cardboard Prototype
We knew that we wanted to use the thinest, lightest structurally sound plywood possible. Back to Google... In the meantime, we progressed onto building an "ugly" plywood prototype out of ¼" plywood from Home Depot. This prototype allowed us to continue the design process into the several individual design elements needed. 1) Plywood choice and strength characteristics, 2) roller and drivetrain design, 3) front suspension design, 4) cockpit design, 5) exterior foam and aerodynamic shape. Our research for plywood material discovered 3mm Okoume was the best strength/weight/price ratio. That led us to Boat Builder Central and Reid McRee. Reid was and is an incredible resource! He asked that our experience to be documented so that many teams can follow, learn, compete, and see that they can take a custom car on with little skills but a lot of dedication.

Our "ugly" prototype was measured and put into a CAD program so that Boat Builder Central could CNC cut our sheets of 3mm Okoume. That prototype also produced the shape for the rollbar for the aluminum fabricator to build. We also were able to plan for many other systems of the car including wiring, motor, batteries, seatbelt, steering, wheels, axles, exterior finishes, impact resistance, aerodynamic resistance, seat design, and so on. Reid got us the perfectly cut plywood, the resin, the fiberglass mat, some tips and some confidence. We took a brief pause on this project to go finish our kit car Karma, getting it ready for the Fall 2017 October race. We then painted the aluminum and here we are! More to follow, stay tuned!
Last edited by HHS Greenpower on Tue Nov 14, 2017 7:59 am, edited 2 times in total.

HHS Greenpower
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Location: Huntsville, AL

Re: HHS Scratch-build Custom Greenpower F24

Post by HHS Greenpower » Mon Nov 06, 2017 8:51 pm

Pictures June 2017
Last edited by HHS Greenpower on Tue Nov 14, 2017 8:01 am, edited 1 time in total.

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Re: HHS Scratch-build Custom Greenpower F24

Post by narfi » Tue Nov 07, 2017 12:14 pm

Looks like fun!

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Re: HHS Scratch-build Custom Greenpower F24

Post by Jeff » Tue Nov 07, 2017 3:39 pm

Guys, this is really good stuff!! Happy to see High School level students involved in a project this innovative!! Future Engineers!!! Jeff

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Re: HHS Scratch-build Custom Greenpower F24

Post by Reid » Tue Nov 07, 2017 3:51 pm

HHS Greenpower,

Welcome to the Forum! This is a really exciting build and definitely a first for us here at Boat Builder Central!!! It is really cool to see that kit car racing is still around and awesome to see it taken to the next level with the amount of engineering you all have put into it. I am excited that I was able to be a small part of the process! Please keep posting as many pictures and updates as you can. You will be surprised on the feedback you will get from our Forum members, many of whom are experts in engineering, epoxy/fiberglass work, and machining.

Keep up the good work and I look forward to seeing the future progress!!!

Someone asked me, if I were stranded on a desert island what book would I bring... "How to Build a Boat."
- Steven Wright

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Re: HHS Scratch-build Custom Greenpower F24

Post by DAYTRIP » Tue Nov 07, 2017 4:53 pm

Great job guys! Be sure to ask any questions you might have here.


Re: HHS Scratch-build Custom Greenpower F24

Post by bateau-webmaster » Thu Nov 09, 2017 12:01 pm

Very nice progress there.

As far as arranging your pictures goes, you can click the spot in the message body you want the picture to show up, and click "place inline" (in the attachments tab below the message) and it will put a phpbbcode tag into the message, so that you can order them and arrange them as you see fit. If you have further questions about posting pictures please give us a call at the shop, and ask for me (Jamie). I'll be here until 2 today.

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