Our Build Chronology

Step 1 : Decide on which layout to build first

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

Step 2 : Decide on drive type

Step 1 : Decide on which layout to build first

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 ;>)

Step 3: Create 3D Model

Step 1 : Decide on which layout to build first

Step 4 : Source an engine

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

Step 4 : Source an engine

Step 6 : Select 90 degree gearboxes

Step 4 : Source an engine

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.

Step 5 : Remove engine

Step 6 : Select 90 degree gearboxes

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

Step 6 : Select 90 degree gearboxes

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.

Step 7 : Finalize base components

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.

Step 8 : Start Framing

Step 7 : Finalize base components

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

Step 9 : Set Front gearboxes

Step 7 : Finalize base components

Step 10 : Strengthen gearbox framing

Front gearboxes and steering rack is set in framing.

Step 10 : Strengthen gearbox framing

Step 11 : Set Rear Gearbox and Engine

Step 10 : Strengthen gearbox framing

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

Step 11 : Set Rear Gearbox and Engine

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

Step 12: Start rear framing

Step 11 : Set Rear Gearbox and Engine

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

Step 13: Finalize major rear components

Rear Gearbox mounts , Engine Mounts, swing arm mounts fabricated

Step 14 : Fab Rear Swing arm

Step 13: Finalize major rear components

Rear Swing Arm is fabricated

Step 15: First strength test

Step 13: Finalize major rear components

Step 16: Luggage Volume test

450 lb motor and accessory weight testing.

Step 16: Luggage Volume test

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

Note location setting for air suspension compressors and tank.

Step 17: Fab Driveshafts

Step 16: Luggage Volume test

Step 17: Fab Driveshafts

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.

Step 18 : Fab Exhaust

Step 16: Luggage Volume test

Step 17: Fab Driveshafts

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

Step 19: Major Components Complete

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

Step 20 : First roll

Step 19: Major Components Complete

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

Step 21 : First Fans

Step 19: Major Components Complete

Step 22: Bottoms Up !

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

Step 22: Bottoms Up !

Step 23: Engine Install

Step 22: Bottoms Up !

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.

Step 23: Engine Install

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

Step 24: Prep

Step 23: Engine 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.

Step 25 : First public appearance

2017 Car show. Lots of interest and great people. Thanks to everyone who talked to us, and all the positive energy and comments.

Step 26 : Fan feedback

Step 25 : First public appearance

After listening to the fans, we decided to alter the body style slightly, and create dual intakes with roll bars, instead of the original F1 style intake.

Step 27: Grilling

Step 28: More Fans

Exhaust system coatings require heat treatment. Grill is re-purposed.

Step 28: More Fans

With exhaust finalized, new radiators and sizing can be determined. Note that pivoting steering is in place

Step 29: Mock up body options

Step 30: Body style finalized, start sheet metal templates

Lots of fun creating different body styles, headlight locations, and windshield sizes. Many options, some really crazy.

Step 30: Body style finalized, start sheet metal templates

Wood templates give a real life feel to body. Sheet metal fabrication begins.

Step 31: Rear Panel

Step 32: Begin Front Canopy

Front Fenders and Rear Panels sheet metal starts. Rear panel electric opener is tested- very cool.

Step 32: Begin Front Canopy

Front canopy is framed out. Requires motion diagrams to articulating movement. Sets windshield sizes and rear pins.

Stacking Up

Step 32: Front Canopy Lift

Friend's 1987 Electric Porsche conversion. Next Dragonfly version will be electric example. Starting sketches now anticipating the future :>)

Step 32: Front Canopy Lift

One of two series based linear linear actuators for Canopy lift. Wireless and control unit show on inset.

Step 33: Cold Air Intake

Step 34: Side Vent Space Check

Routing of Air Intake to Side Air Scoop (note CSF Radiator in wheel well)

Step 34: Side Vent Space Check

Quick cardboard verification that rear canopy will open/close

Thanks to our sponsors

CSF Cooling

Air Lift Performance

Thanks to sponsorships from CSF Cooling! Side radiators, small size, performance cooling... who can meet our specialized needs ? Well, meet CSF Racing and High Performance. CSF Radiators | Ultimate Performance Cooling (csfrace.com) They had THE goods, and were generous enough to support our efforts. We are using two CSF All-Aluminum High Performance King Cooler (#7065), one on each side. Very nice!

Air Lift Performance

When we made the first Dragonfly design, we needed to select an air system for design detailing. Unfortunately, that was many years ago and the old K-Sport control system had no ride height control and was slowly failing. Searching for a replacement that could support our radical needs, AIR LIFT has graciously agreed to help sponsor our endeavors. Their new systems are really slick. Check out AIRLIFT at https://www.airliftperformance.com/ . More to come as we set up the system.