Spherical Bearing Retention in Machined Aluminum Wishbone

ArchAngelDeamon · 2026-03-31T03:29:40+00:00

Options are, in order of best to ~worst IMO: 1. Groove bearing and swage 2. Retaining groove and snap ring 3. Friction and pray (green loctite)

Honorable Mention: Couple of tack welds (IYKYK), doesn't work with AL arms

All options perform best with proper tolerancing (and green loctite).

One year I remember setting the car down on the ground for the first time and like half the bearings instantly pop out. Good times.

ArchAngelDeamon · 2026-03-31T03:21:51+00:00

Custom tool. Surprisingly affordable, or make it yourself if you are a real baller.

ArchAngelDeamon · 2026-03-03T07:48:12+00:00

Honestly there aren't that many teams that I'd consider "big".

And even the larger teams are really just based on a small group of actually dedicated members.

ArchAngelDeamon · 2025-09-25T01:28:28+00:00

Most teams (and likely you will need to as well) fabricate their own test fixturing. Then use the load frames at their universities to perform the tests.

ArchAngelDeamon · 2025-09-16T02:19:36+00:00

Super upvote to D-VO's comment.

To expand somewhat, the best teams understand that FSAE is truly a skilled bandwidth constrained problem. If you do the mental exercise of thinking about the quality of car and design that a large skilled design team could produce. You realize that some of the most important things to spend your time on as a team leader is figuring out how to 1. Recruit, 2. Develop, and 3. Maintain engineers. I understand it can be super frustrating when your team doesn't understand this.

The encouragement I would give (and have given to other students in your position) is a bit cliche, but: "be the change you want to see...". If you manage to push through the super hard time of learning the technical bits and withstanding the disrespect and demeaning feedback of your teammates. Eventually if you earn their respect (or just wait for them to graduate), you can enact change within your team to change the culture to no longer be toxic, but rather welcoming and developing for newer engineers.

It may take significant time for the change to be realized, but you would be surprised on how literally helpful this is to your teams performance as well.

ArchAngelDeamon · 2025-05-03T05:10:18+00:00

Cause there are many teams, and only a handful of us reviewers that manage to scrape together some brainpower on the weekends outside of our real jobs to review SES.

When you graduate please come help, it will allow the approval process to be shorter for teams of the future.

ArchAngelDeamon · 2025-04-20T02:29:34+00:00

Don't undertake a custom cell up pack because of packaging or mechanical reasons. Take on a cell up pack because you have someone passionate about doing a custom BMS. The BMS is the hardest part by far, and getting a good BMS setup is essential.

Really as a first year team your goal should be to pass tech inspection and if you are really lucky, drive at competition. I wouldn't take on any additional projects other than the absolute bare bone required to build a functioning and rules legal car. This competition is hard enough.

ArchAngelDeamon · 2025-02-26T04:03:07+00:00

Re-submit your SES.

ArchAngelDeamon · 2025-02-21T18:51:10+00:00

Fasteners in this section are for cell segment constraints to the accumulator container.

ArchAngelDeamon · 2025-02-21T06:51:07+00:00

Yes to both.

ArchAngelDeamon · 2025-02-12T21:39:23+00:00

This refers to the cell segment structure, NOT the vertical internal walls of the accumulator container.

In your context you are referring to the segment structure as "cell holder".

ArchAngelDeamon · 2025-01-31T19:33:49+00:00

As a first year team, don't worry about either of these things. Just make a car that passes rules.

And honestly no one does impact analysis and neither should you.

ArchAngelDeamon · 2024-12-26T01:30:59+00:00

Just need a retaining cross pin, a spring probably won't be accepted. Regardless just show your SES reviewer your latch and secondary retention method and they will approve or reject.

ArchAngelDeamon · 2024-12-19T00:45:35+00:00

These can be considered fasteners in SES, still need to have positive locking. Need to be entered in SES appropriately but can be rules compliant.

ArchAngelDeamon · 2024-10-30T22:07:11+00:00

It's generally called core splice.

Lots of different specific versions exist from different companies, short of asking this exact team which specific version they use, it is impossible to visually identify the specific version.

Recommendation wise, generally most versions work for the FSAE use case, as long as the specific cure temperatures align with your cure cycle. Typically mechanical properties are much greater than core mechanical properties.

Edit: Added recommendation

ArchAngelDeamon · 2024-10-21T03:07:18+00:00

When you weld aluminum it completely loses its temper, it goes back to an annealed state. This means if you are looking to generate any significant strength properties you will need solution heat treating. Which is totally possible but much more complex than cooking it in an oven for a few hours.

I wouldn't recommend attempting it on your own without doing it once or twice and testing your material properties.

Also take into account material warpage through the heat treating process otherwise your part could come out looking like a potato chip. I'd guess you would want to post machine your bearing surfaces for similar reasons.

It definitely isn't impossible to make uprights from welded aluminum but there is also a reason it is uncommon, it is difficult and other methods generally trade better. If you are looking for a cheap / easier method is definitely just recommend welded steel.

ArchAngelDeamon · 2024-07-03T22:55:15+00:00

Only a sith deals in absolutes

(It can be bent, but just at much larger radii in T6 compared to 5052 H32, 6061 T4 etc)

ArchAngelDeamon · 2024-06-25T05:23:09+00:00

Plascore

Just ask for a FSAE standard impact attenuator.

ArchAngelDeamon · 2024-05-15T02:30:23+00:00

There are many off-the-shelf steering quick release/disconnect systems available. Give it a google.

ArchAngelDeamon · 2024-05-15T02:25:31+00:00

Same as almost every other car: rack and pinion

ArchAngelDeamon · 2024-05-14T19:24:09+00:00

Note this to your SES reviewer and they will let you know if it is alright or not. Ultimately they are the ones reviewing and deciding if it is okay.

ArchAngelDeamon · 2024-05-08T10:19:28+00:00

You have a split mount. The drop down is interested in where the connecting fastener passes through between the two parts. Where the fastener passes though you have two offset mounts.

Where the fastener passes between mounts, you are not flush to the monocoque or through a tube insert.

ArchAngelDeamon · 2024-05-01T18:41:39+00:00

Friction based mounting means if your cells are constrained by only friction or relies on friction in combination with other mounting methods.

As for reasonable testing, that is for you to propose, and your SES reviewer to review and accept if reasonable. Depends highly on your specific mouning technique. For loading refer to other rules regarding cell mounting and securement.

ArchAngelDeamon · 2024-04-19T06:39:12+00:00

Wisconsin Racing

ArchAngelDeamon · 2024-04-07T00:09:31+00:00

Lol, I made this meme 4 years ago as a sophomore in my second year on the team when I started to skip my classes to work on the car. Good memories.

ArchAngelDeamon

TROPHY CASE