Our Build Chronology

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We decided to do a two person, side by side seating.  Good for a driver and a fun partner next to you !

A shaft drive approach would prove that routing and gearboxes were feasible.  Since electric was not viable when the concept started, we decided to use a gas engine.  Electric will be for our next model ;>)  

Completed by Alex in AutoCAD, the 3D model was a first pass at the mechanical arrangement.  A 3D 'Printed' model was produced.  

To do more details, we needed to obtain the exact engine to be used.  But where to find something we could afford ?  A Honda Civic SI engine from a salvage vehicle became our donor.  But we did need to get it running before pulling it out.

Engine removal required tracing and tagging of related of the electrical and mechanical components.   

Four right angle gear boxes were required.  Unfortunately, for this concept build, we could not afford to have anything made, so we sourced some spiral bevel 1:1 gears with roller bearings.    Chunkier and heavier than production would be, but good and solid for our concept.

 This picture show the basic arrangement of the wheels, seats, engine, gearboxes, driveshafts, and gas tank.  With engine and gearboxes selected, weight calculations and arrangement details are finalized. 

Would there be enough room ?  What would the seats feel like ?  First framing sets seat and front wheels.  

Front gearboxes and steering rack is set in framing.

 Front/Rear/Side strengthening of core around gearboxes, steering rack, and anti-roll bar.  

Set location of rear gearboxes and engine. This finalizes shaft lengths, angles, and weighting.

Rear framing begins.  Gas tank, swing arm must be accommodated.

Rear Gearbox mounts , Engine Mounts, swing arm mounts fabricated

Rear Swing Arm is fabricated

  450 lb motor and accessory weight testing.  

 Trunk space for Lawn Chairs and Cooler check.  Must have for a fun vehicle !  

Note location setting for air suspension compressors and tank.

 Six driveshafts (3 each side), with CV joints to accommodate motor vibration damping and wheel travel.  In production, these would be shorter/longer versions of what is in your car today. 

 Exhaust with stainless mesh sections for vibration damping, muffler, and Cat  to keep clean air :>)   

 Last picture of open framing with major components.  Sheet metal to complete drivers cabin begins. 

 Dragonfly stands on it's own wheels for the first time, and takes a peek outside.  

 Front Bumper set, and front framing locations begin.  Air suspension installed.  Raw chassis will be complete once front framing is finished.

With raw chassis complete, major components are removed, and chassis is flipped for bottom work.  Once completed, frame will be painted and sealed on bottom before returning upright.

Bottom of chassis is completed, and flipped upright.  Major components will begin final install.  Here, engine goes in for final install.

A fan suggests appearing at car show.   Idea of showing chassis is interesting to many.  Decision made, chassis components are installed and prepped for show.  With only 4 weeks to complete, feels like TV show build.