1 Chassis

USER MANUAL B. Chassis

Release 6.0 / 2010

INDEX 1.CHASSIS ........................................................................................................... 4 GENERAL AGREEMENT AND WARRANTY ............................................................ 5 FIXED PARTS .................................................................................................. 5 SAFETY WHEEL TETHERS ..................................................................................... 6 SET-UP .............................................................................................................. 7 MICHELIN TIRE INFORMATION .......................................................................... 7 SUGGESTED SETUP.......................................................................................... 7 SETUP ADJUSTMENT ........................................................................................ 8 SETTING THE VERTICAL SPRING PRE-LOAD......................................................... 9 FRONT ANTI ROLL DEVICE AND ROLL PRELOAD ................................................. 10 BELLEVILLE STACK CONFIGURATIONS .............................................................. 11 SETTING THE FRONT ROLL PRELOAD................................................................ 12 CASTOR ....................................................................................................... 13 FRONT SUSPENSION PICK-UP POINTS .............................................................. 14 STEERING WHEEL: .......................................................................................... 15 STEERING ASSEMBLY ..................................................................................... 15 STEERING WHEEL HEIGHT .............................................................................. 16 REAR SUSPENSION ......................................................................................... 18 ROLL CENTER AND ANTISQUAT OPTIONS.......................................................... 18 FLOOR EXTENSION MODIFICATION .................................................................. 20 FLOOR EXTENSION MODIFICATION .................................................................. 21 REAR ANTIROLL BAR STIFFNESS...................................................................... 22 REAR SUSPENSION PICK-UP POINTS ................................................................ 24 SET-UP ............................................................................................................ 25 RIDE HEIGHT CHECK AND REFERENCES............................................................ 25 DRAWINGS ................................................................................................... 26 NOSE FITTING ................................................................................................ 29 AERODYNAMICS.............................................................................................. 30 DEFINITIONS ................................................................................................ 30 AERODYNAMICS FEATURES OF THE CAR ........................................................... 30 FRONT WING ASSEMBLY................................................................................. 31 MAIN BODY AND UNDERWING ......................................................................... 34 REAR WING ASSEMBLY................................................................................... 36 LOW DOWNFORCE AERODYNAMIC CONFIGURATION (LAC) .................................. 42 POLAR DIAGRAM OF THE CAR.......................................................................... 43 AERO MAPS .................................................................................................. 44 COOLING INLET BLANKING ............................................................................. 46 POLAR DIAGRAM OF THE MAIN ADJUSTABLE DEVICES ........................................ 47 OIL SYSTEM .................................................................................................... 48 OIL LEVEL AND CHARACTERISTICS .................................................................. 48 HYDRAULIC OIL SYSTEM................................................................................. 49 ENGINE COMPARTMENT COOLING .................................................................. 50 EXTRACTABLE SEAT ........................................................................................ 52 CARBON SHELL AND LEG STRAP POSITION ....................................................... 52

B-2

Release 6.0 / 2010 BLACK SOCKET POSITION............................................................................... 54 SIDE BELTS .................................................................................................. 54 DRIVER SEAT DIMENSION .............................................................................. 55 FUEL SYSTEM .................................................................................................. 56 EXTINGUISHER SYSTEM LAY-OUT ................................................................... 56 EXTINGUISHER SYSTEM LAY-OUT ................................................................... 57 DETAILS....................................................................................................... 57 TESTING ...................................................................................................... 58 PRECAUTIONS............................................................................................... 58 SBS 30 – DRY BATTERY................................................................................... 59 CHARGING PROCEDURE.................................................................................. 59 SAFETY NOTES .............................................................................................. 59 SWITCH PLATE................................................................................................ 60 SWG & CONVERSION TABLE............................................................................ 61 SHEET METAL THICKNESS .............................................................................. 61 UNIT CONVERSION TABLE .............................................................................. 61

B-3

Release 6.0 / 2010

1.CHASSIS

B-4

Release 6.0 / 2010 GENERAL AGREEMENT AND WARRANTY Motor racing is not covered by warranty due to the intentional choice of drivers to race in a dangerous environment DALLARA indicates that, under normal operating conditions, this model of car, when new, would not show failure in structural components before it has completed around 10 000 Km. This holds true if necessary maintenance and checks are provided and if the car has no previous accidents. DALLARA is not responsible for incorrect chassis repairs, if made outside its factory or in centres not authorized by DALLARA. Chassis should be checked for structural failure not later than two years after delivery from the DALLARA factory, and after each major accident. After the first check or after any major accident it is mandatory to check the chassis every year in a centre authorized by DALLARA.

FIXED PARTS Teams are not allowed to use, test or run chassis parts not supplied by “Magasin Pièces détachées Compétition Renault Sport” except for the parts related to driver comfort in the cockpit. Main fixed parts are the following ones:         

Springs (front: between 900 and 1600 lb/in, rear: between 900 and 1700 lb/in). ZF SACHS Race Engineering Dampers FBT23 (front) and FBT24 (rear) Differential ramps: 20°/60°; 45°/80°; 45°/45° and 45°/20° only allowed Front anti roll bar with 2mm Belleville springs. Rear T-shaped anti roll bar: 20x2.25, 25x1.5, 30x1.5, and 30x5 mm only are allowed Carbon / Carbon Clutch (140mm diameter) Carbon discs and carbon brake pads Brake master cylinders Seat harness

B-5

Release 6.0 / 2010

SAFETY WHEEL TETHERS

FRONT TETHERS – WHEEL SIDE

FRONT TETHERS – CHASSIS SIDE

REAR TETHERS – WHEEL SIDE

REAR TETHERS – CHASSIS SIDE

Wheel side installation:  Front and rear: eyelet trapped around the brake calliper bosses. Chassis side installation:  Front: front tether eyelet trapped around lower wishbone front leg central bracket;  Rear: Tether eyelet trapped around the suspension brackets. Use a specific washer create enough space for the tether eyelet as described below: Renault Sport and Dallara recommend replacing wheel tethers if one or more of the following conditions are met:   

The cable has been on the car for 12 months The car has been in an accident. The cable has been damaged, i.e. the braid, tape or mould have been damaged exposing the fibre, the cable or cover has been cut, the cable has been over-tensioned (cables are not designed to be exposed to any load prior to an accident

B-6

Release 6.0 / 2010 SET-UP

MICHELIN TIRE INFORMATION Tire dimensions depend on tyre pressure, rim width and camber angle. The stiffness values are based on the recommended inflating pressure (hot tyres). FRONT 26/64/13 1994 317.4 295.2 329.5 8.7 1.5

Specification Static circumference (mm) Unloaded radius (mm) Average loaded radius (mm) Width Weight (kg) Hot tire pressure (bar)

REAR 32/66-13 2060 327.8 308.5 382.5 10.2 1.5

SUGGESTED SETUP The set-up considers the complete car, with all liquids [water, oil], driver and 30 kilograms of fuel, ready to race. The front anti-roll setting pre-load is ‘double stiffness’ pre-load, for details look at the FARB pages.

Ride height Camber Castor (apparent) Toe (total two wheels) Springs Vertical pre-load Damper free gap Damper setting LS Damper setting HS Roll centre setting Anti Roll setting Roll pre-load Ramps Differential setting Plates Preload

mm deg deg deg Lb/in mm mm

FRONT 23 -3.5° 0.0° 40’° OUT 1600 5.5 turn 4 B8 R10 B10 R6 STD

notches

mm

B-7

2 -

REAR 38 -2.5° 20’ IN 1300 0 turn 11 B10 R2 B8 R8 3-A 20x2.25 Titan P3 Acc 20° Bra 60° 8 0.4

Release 6.0 / 2010

SETUP ADJUSTMENT POSITIVE CHANGE IN: Ride Height Toe Camber Castor

PUSHROD ADJUSTER Ride Height change +1 barrel Camber change (deg) TURN Thread size TOE ADJUSTER (PER WHEEL) toe change (deg) thread step CAMBER +1mm SHIM toe change (deg) CASTOR ADJUSTER Castor change (deg) Thread step & size Ride height change +1TURN Camber change (deg) Toe change (deg) SPRING PLATFORM thread step (mm) +1TURN height change (mm) RATIOS WHEEL/SPRING RATIO (vertical) WHEEL/BELLEVILLE RATIO (lateral) WHEEL/DROP LINK RATIO (roll) ROLL CENTRE HEIGHT [from ground]

MEANS: car moves up toe-out upper part of rim outward lower part of rim points ahead FRONT

REAR

6.00mm

7.56mm

0.1°

0.16°

M20x2R+7/16UNF20L=3.27mm

M20x2R+1/2UNF20L=3.27mm

0.6° (per turn) 1/4UNF-24 0.28° 0°

0.31° (per 1mm shim)

0.34° 1.06mm-1/4UNF-24 +0.20 mm +0.19° 0°

0.42° 1.27mm-1/2UNF-20 +0.42 mm +0.14° 0.05°

1.5 1.31

1.5 1.72

0.874 1.704 --

1.15 ---1.61

7.4 mm [down]

STD: 32mm [up]

0.24° 0°

Spacers to adjust camber and rear toe are available in the following thickness.  FRONT: 1.0, 1.5 and 2.0 mm  REAR: 0.5, 0.8, 1.0, 1.2, 1.5 and 2.0mm. Combine these spacers to make fine adjustments. At the rear, you can adjust toe with differential spacers. At the front, because of the “mono” geometry, when the axle moves vertically by 1mm, the vertical spring is compressed by 1/0.87 mm. When the difference in wheel vertical movement, from side to side, is 2 mm, the Belleville stack is compressed by 1/1.704 mm.

B-8

Release 6.0 / 2010 FRONT SUSPENSION

SETTING THE VERTICAL SPRING PRE-LOAD       

Mount the spring with the spring platform C just in contact with the spring. Mount the damper-spring assembly on the car and put the car with the driver seated on the set-up floor. Bounce the car a few times to settle it down. Be sure that the droop-stop A is not in contact with the plate B. Set the desired ride height with the pushrod adjusters. Turn the droop-stop A in contact with plate B and tighten with its counter-nut. Turn spring platform C by the amount of turns to get the desired pre-load force

B-9

Release 6.0 / 2010

FRONT ANTI ROLL DEVICE AND ROLL PRELOAD There are three different ways of setting the front anti-roll Belleville washers. The platform thread step is 1.5 mm. There are 15 notches per turn, hence 0.1 mm preload per notch. [1] Select a stack configuration and turn the platforms (both sides) until just in contact with the stack. In this configuration there is no pre-load and the roll stiffness is the nominal stack stiffness. For example: the configuration > + 5 notches “ has 0.5mm of roll preload and, up to 0.5 mm of side rocker movement, the stack stiffness is 761x2=1522kg/mm. [3] By turning both platforms (use notches as reference) and by locking the two extra locknuts the system is infinitely stiff, this means the rocker will not move as long as the force is lower than the pre-load. Once the side force overcomes the pre-load, the stiffness is the nominal stack stiffness. Both pre-load settings (2 and 3) generally help for sharper turn-in. No pre-load settings (1) can make the tyres last longer and make the car easier to drive. Above the pre-load, the stiffness gets back to the nominal stack stiffness. The driver may prefer not to overcome the pre-load in certain conditions (turn-in…) and to overcome the pre-load in some other conditions (mid corner, curbs…). Set accurately the transition point of ‘pre-load / no pre-load’ since the consequently stiffness variation is sudden and reflects immediately on the balance You can combine different stacks in series to achieve a progressive load / displacement characteristic. Pay attention to the following:    

Total length of the combined stack should never be more than 28mm. The clearance between the platform and the rocker (B) should not be more than 6.5mm when the platform just touches the Belleville stack, with no pre-load. For any Belleville stack, in running conditions, the total of the rocker lateral displacement plus the chosen pre-load must never reach the "Maximum Deflection" (see Table below), to avoid the side of the rocker to “bottom-out” suddenly. Belleville thickness is 2.0 mm

B-10

Release 6.0 / 2010

BELLEVILLE STACK CONFIGURATIONS Stack configuration

Stack stiffness [kg/mm]

Stack stiffness (preload) [kg/mm]

Stack length [mm]

Max deflection [mm]