MacKenzie Angeledes
A)Proposed Budget
i)Parts Suppliers, Substantive Costs, and Buying Issues
The coilover dampening shocks will be sourced from EMPI – a company that specializes in aftermarket components for the Volkswagen Beetle. They produce an adjustable coilover shock with an extended length of 16.75 in and a compressed length of 11.25 in. The unit is entirely self-contained and can be purchased for less than $100.00 from various online parts suppliers.
The lower control arms will have to be produced by using 1-in-square steel tubing. The material, if not available from the Central Washington University Machine Lab, can be acquired from a metal supplier. The tubing will be cut to length, notched, and then the joints will be welded forming the 90-degree angle to accommodate the existing axle mounts. The axle mounts may need to be modified slightly in order to accommodate the frame connections, discussed below.
The frame mounting connections can be purchased, with bushings and bolts, from online supplier Summit Racing for $7.00 including shipping. Six of these connectors will be needed. These connectors will be welded to the frame in the welding technology lab. If necessary, a flat plate may need to be fixed to the frame prior to welding the brackets. At the ends of the lower control arms, nearest to the axle mounts, there may be a small interference between the brackets and the lower edge of the axle mount. If necessary, the end of the axle mount can be milled or cut down to accommodate both the mount and bracket.
Shipping for both the EMPI-sourced shocks and Summit Racing brackets are approximately two weeks from time of payment, according to their respective websites. Square tubing, if not available, can be acquired locally from a metal supermarket, typically the same day as needed.
ii)Labor Rates, Outsourcing Rates, and Estimated Costs
The current estimated labor rate for a qualified welder or machinist is around $100 USD per hour of work. By using outsourced parts, this limits the budget required for labor. A detailed description of costs is as follows:
6x Coilover Brackets............................................................................. $7.00 USD/ea
2x EMPI Coilover Shocks....................................................................... $100 USD/pair
1x 6-feet of 1-in square steel tubing (A513).......................................... $15.00 USD/6 ft
2x 1 hour - Labor – Welding/Cutting/Assembly..................................... $100 USD/hr
Estimated Total Cost............................................................................ $358.00 USD
In reality, additional costs for various hardware pieces necessary for completion may add to this estimate. By using the machine lab resources, costs may be cut considerably. If hardware is available to be donated, more costs can be minimized.
iii)Labor
The anticipated tasks that would require additional assistance are as follows
Cutting of the square steel stock to build the lower control arms
Welding the square stock (MIG/TIG/O.A. welding)
Welding the coilover brackets to the existing frame
Welding the coilover brackets to the lower control arms
Drilling the square steel stock to accept the motor and axle mounts
Assembly of the suspension to the frame
Modification of the existing axle mounts (if needed)
iv)Estimated Total Project Cost
The estimated total project cost, with additional components as necessary, is approximately $400 USD. As stated previously, donated resources will help to reduce this cost.
v)Funding Sources
The majority of the funding required by this project will be provided by the Electric Vehicle club’s student account. Any additional resources that are not eligible will be purchased by way of personal monetary funds.
B)Proposed Schedule
i)High Level Gantt Chart
ii)Task Flow and Timing
Further elaboration on the Gantt chart, including a high resolution copy and task breakdown are featured in Appendix E.
iii)Task Dates and Deadlines
Major task dates are shown by week in the Gantt chart above. Significant dates include the submission of the completed proposal at the end Fall Quarter 2015, the completion of construction at the end of Winter Quarter 2016, and the presentation of the project at the SOURCE conference during the 7th week of Spring Quarter 2016.
iv)Deliverables and Milestones
Major deliverables and milestones are highlighted in red on the Gantt chart above. The success of the project is also dependent on the completion of the project proposal, the completion of the construction and assembly, and the presentation of the project at SOURCE.
v)Estimated Total Project Time
Based on the Gantt chart above, the approximate total time invested for the completion of the project is 103.5 hours. It should be noted that this is an estimate for total time invested. Based on unforeseen factors, it is reasonable to suggest an additional 20 hours of work.
C)Project Management
i)Human Resources
The Central Washington University Electric Vehicle club has offered to work on the assembly of the project. Additionally, the Teachers’ Assistant in the mechanical engineering department has also offered help on some of the specific manufacturing issues – namely hardware acquisition and welding of the lower control and bracket.
ii)Physical Resources
The physical resources necessary for the project include the machining lab, the senior project room in the Hogue Technology building at the Ellensburg CWU campus, and the welding lab of the same building.
iii)Soft Resources
Software for this project is provided for educational use by the Central Washington University site licensing. The software used includes the Microsoft Office Suite (Word, Excel, Power Point), AutoDesk AutoCAD, and Solidworks.
iv)Financial Resources
Hardware for this project will be purchased at the expense of the Electric Vehicle club and by way of personal monetary contributions. Labor costs, if at all possible, will be minimized by utilizing the on-campus helper staff to complete specific tasks in manufacturing. Through communication with the managing officers of the Electric Vehicle club confirmed that hardware and material purchased for use on the project is eligible for refund provided there is adequate receipt information available for the purchases.
