We Limit Our Materials

A core XM (eXtreme Manufacturing) practice is to only use materials that can be inexpensively iterated (re-made) in less than a week, and then choose the fewest number of different materials / processes practical in order to build deep experience quickly.
Here’s the list of stuff to make the car:
1) aluminum, 6061-T6. stock shapes and extrusions with the fewest cuts or machining operations practical.
2) Carbon fiber for curvilinear shapes. Carbon wrapped over closed-cell foam.
3) White faux fur for all soft surfaces (this is especially awesome).
4) Flat, labeled AS1 safety glass for all glazing.
1A) extruded aluminum 6061-T6, 4″X4″ square tube, 1/8th inch thick wall. (for those outside the US, we can ship it to you or you can use a similar metric size like the team in New Zealand has done). Drilled and or cut.
1B) Aluminum plate, 6061-T6, 1/4″ thick. CNC waterjet cut.
1C) Bolt aluminum together with a single standardized fastener. 3/8ths, 24 thread, grade 8 bolt with 1″ OD steel washers 1/8th inch thick, and nylon lock nuts.
1D) Hinges are all 3/8ths 24 thread spherical rod end joints (heim joints) with a minimum radial load capacity of 4,000 lbs.
2A) to do it in less than a week, shape the foam then wrap it directly in carbon leaving the foam attached, or wrap the foam in syran wrap then carbon so that the foam may be re-used.

2 thoughts on “We Limit Our Materials

  1. Where do you source 6061-T6, 4″X4″ square tube, 1/8th inch thick wall tubing? Everything I’ve found in 4″x4″ is at least 3/16 (0.185″). Are you sure you didn’t mean 3/16th?

    1. Christopher,

      I forwarded your question to the Team Forum and received the following responses so far.

      4 x 4 x 0.125 inch wall, 6061 T6, 20 foot lengths, are stocked in Canada by Russell Metals.http://www.russelmetals.com/en/Products/AluminumExtrusions/Pages/Squares.aspx

      Joe has ordered several times from OnlineMetals.com, but their website does not appear to list it right now. I’m not sure if that is an out-of-stock issue, or if they no longer carry that size.

      We have not ordered from this site so far, but they appear to list the product http://www.speedymetals.com/c-8379-square-tube.aspx


      I order mostly from Coast Aluminum to save money, about half the price of Online Metals if I order 500lbs or more at a time.


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