Building a NASA NP01 Prototype the Right Way with Stoptech! Part 1


The basic tube chassis was set on this simple work table and some of the interior sheet metal was checked for fit.  The black panels are a heavy duty composite and serve as a crash attenuating stucture. The tube frame was shipped with these already riveted in place. The window nets were also test fit at this time. It was decided to assemble the car inside out as much as posible to logically make things easier.
The rear firewall was fit checked. Some engine peripherals are hung on the firewall so it's important that it be fitted to the car early in the process.  The car's tin work is pre cut with the mounting holes pre drilled.  It is expected that the person assembling the car drill holes in the chassis and pop rivets the panels in place.

The StopTech crew decided that doing this was not the best way to assemble things from a repairability and maintainability perspective. Instead of using pop rivets, StopTech used riv nuts and small stainless steel button head allen bolts to hold the panels in place. This way any panel can be quickly and easily removed from the car.

You can see the start of mounting the footbox sheetmetal here. You can see the first allen bolts holding the panel in place.  The steering rack was installed at this point.
These fiberglass panels are about a 1/4″ thick and are designed to crush in a controlled way in a severe crash to help protect the driver. 
Once the aluminum panels around the footbox were fitted, the steering shaft was installed. 
The steering shaft mounting was redone by the Stoptech crew to have a straighter shot to the steering rack. This reduces motion being lost and friction generated due to U-Joint angularity. This is improves steering feel. 
The AiM MXL datalogging dash, quick release Momo steering wheel, radio and window net mounts were added at this time. 

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