Chassis

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Chassis Open a new part with model units set to millimeters. Select the three planes in the feature tree and make them visible by clicking on the glasses.

Change the name of the Top Plane Double click on the Top Plane in the feature tree. Change the name into: BOTTOMPLANE CHASSIS Change the name of the Front Plane Double click on the Front Plane in the feature tree. Change the name into: MIDPLANE CHASSIS

Select the MIDPLANE CHASSIS and create a sketch by clicking on the 2D Sketch icon

Insert a sketch underlay For this part of the chopper we use a hand made sketch as underlay to simplify the design process of the chassis. Go to: Tools > Sketch Tools > Sketch Picture Select “Chopper Underlay.Jpeg” Underlay.Jpe g” Click: open

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Change the position of the underlay to ensure that the underside of the chassis is equal with the BOTTOMPLANE CHASSIS.

Change the dimensions of

and

as shown in the picture.

Click OK

Change the name of Sketch1 Double click on Sketch1 in the feature tree. Change the name into: CHASSIS UNDERLAY | Page

Select the MIDPLANE CHASSIS and create a new sketch Hide the underlay if this is appropriate Click on “CHASSIS UNDERLAY” in the feature tree and hide this by clicking on the glasses. Use the underlay whenever you want. Draw the sketch as shown in the picture.

Close the sketch. Select the MIDPLANE CHASSIS again and create another sketch

Draw the sketch as shown in the picture.

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Hide the underlay if this is appropriate

Close the sketch.

Select the BOTTOMPLANE CHASSIS and create a new sketch Draw the sketch as shown in the picture.

Close the sketch.

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Create a projected curve

Go to: Insert > Curve > Projected Selections

: Sketch2 and Sketch3

The yellow line is a combination of Sketch2 and Sketch3. Click OK

Create a sweep Go to: Insert > Boss/Ba se > Sweep Profile Path

: Select the green Sketch1 : Select the pink Curve1

Click OK

Mirror Sweep1 Go to: Insert > Pattern/Mirror > Mirror Mirror Face/Plane

: MIDPLANE CHASSIS

Select the “Features to Mirror” option Features to Mirror

: Sweep1

Click OK

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Select the Right Plane and create a new sketch Draw the sketch as shown in the picture.

Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1

: Blind

Ensure that the offset is directed outwards as shown in the picture. If not, click “Reverse direction” Change

into 22 mm

Click OK

Select the green surface as shown in the picture and create a new sketch Draw the sketch as shown in the picture.

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Create an extruded cut Go to: Insert > Cut > Extrude Direction 1

: Up To Next

Click OK

Create a chamfer Go to: Insert > Features > Chamfer Select the green edge as shown in the picture. Select the “Distance – distance” option. Change

into: 90 mm

Change

into: 44 mm

Click OK

Create nine fillets Select the green edges as shown in the picture. Go to: Insert > Features > Fillet/Round

> 25 mm

Click OK | Page

Create two large fillets Select the green edges as shown in the picture. Go to: Insert > Features > Fillet/Round

> 50 mm

Click OK

Create a new plane parallel at the MIDPLANE CHASSIS Go to: Insert > Reference Geometry > Plane Select the MIDPLANE CHASSIS Select the green Vertex point in the picture

of Fillet1 as shown

Click OK

Select the new Plane1 and create a new sketch Draw the green vertical construction line. Fix the construction line at the corners of Fillet1 as shown in the picture and detail.

Detail | Page

Show the underlay if this is appropriate Draw the spline

as shown in the picture.

Fix the right side of the spline at the midpoint of the vertical construction line and make the spline tangent

at the horizontal construction line as shown in the detail.

Detail

Close the sketch.

Select the green surface of Extrude1 and create a new sketch Draw the sketch and make the circle concentric shown in the picture.

with the green radius as

Close the sketch. | Page

Create a sweep Go to: Insert > Boss/Base > Sweep Profile Path

: Select the green Sketch7 : Select the pink Sketch6

Click OK

Select Plane1 and create a new sketch

Draw the sketch as shown in the pictur e.

Close the sketch.

Select the green surface of Extrude1 and create a new sketch

Draw the sketch and add a concentric relation with the green arc as shown in the picture.

Close the sketch.

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Create a sweep Go to: Insert > Boss/Base > Sweep Profile Path

: Select the green Sketch9 : Select the pink Sketch8

Click OK

TIP: An underlay could help you to design y our 3D models in the correct dimensions and proportions. This could be very helpful during the design process of a product. Before you start with 3D modeling, we recommend you to sketch the concept by hand first. You could also use a photo as underlay and avoid a lot wasted time and frustration. Think twice, do once!

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Select Plane1 and create a new sketch Draw the sketch as shown in the picture.

Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change

: Midplane into 44 mm

Click OK

Select the green surface of Extrude3 and create a new sketch Draw the sketch as shown in the picture.

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Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1

: Blind

Ensure that the offset is directed outwards as shown in the picture. If not, click “Reverse direction” Change

into 223 mm

Click OK

Create a dome Go to: Insert > Feature > Dome Select the green face of Extrude3. Change the Distance

into 10 mm

Don’t select the Elliptical dome option Click OK

Select the MIDPLANE CHASSIS and create a new sketch Show the underlay if this is appropriate. Draw the sketch as shown in the picture.

Close the sketch. | Page

Create a new plane parallel at the Right Plane Go to: Insert > Reference Geometry > Plane Select the Right Plane Select the green Vertex point as shown in the picture.

of Sketch12

Click OK

Change the name of Plane2 Double click on the new Plane2 in the feature tree. Change the name in: FRONTPLANE CHASSIS

Select the FRONTPLANE CHASSIS and create a new sketch Draw the sketch as shown in the picture. Make the midpoints of the circles coincident at Sketch12.

Close the sketch.

Create a sweep Go to: Insert > Boss/Base > Sweep Profile Path

: Select the green Sketch13 : Select the pink Sketch12

Click OK

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Select the MIDPLANE CHASSIS and create a new sketch Draw the sketch as shown in the picture.

Create an extruded cut Go to: Insert > Cut > Extrude Direction 1 Change

: Mid Plane into 60 mm

Click OK

Create a new plane parallel at the BOTTOMPLANE CHASSIS Go to: Insert > Reference Geometry > Plane Select the BOTTOMPLANE CHASSIS. Change the Offset Distance

into 185mm.

Ensure that the offset is directed to above. If not, click “Reverse direction” Click OK | Page

Select the new Plane2 and create a new sketch Draw the sketch as shown in the picture and detail. Ensure that the horizontal construction line is fixed at the origin.

Close the sketch.

Detail

Select the MIDPLANE CHASSIS and create a new sketch Draw the sketch as shown in the picture. Show the underlay if this is appropriate. Ensure that the spline

is fixed at the middle of the circle of Sweep1.

Close the sketch.

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Create a sweep Go to: Insert > Boss/Base > Sweep Profile Path

: Select the green Sketch15 : Select the pink Sketch16

Click OK

Select the MIDPLANE CHASSIS and create a new sketch Draw the sketch as shown in the picture.

Create a revolved cut Go to: Insert > Cut > Revolve

Axis of revolution

: Select the green line as shown in the picture.

Click OK

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Select the MIDPLANE CHASSIS and create a new sketch Draw the sketch as shown in the picture and detail.

Detail

Create a revolve Go to: Insert > Boss/Base > Revolve Axis of revolution

: Select the green construction line as shown in the picture.

Click OK

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Select the MIDPLANE CHASSIS and create a new sketch

Draw the sketch as shown in the picture and detail.

Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change

: Midplane into 340 mm

Click OK

Create fillets on Revolve1 and Extrude6 Select the green surfaces of Revolve1 and Extrude6 as shown in the picture. Go to: Insert > Features > Fillet/Round

> 2 mm

Click OK | Page

Create a new plane parallel at the MIDPLANE CHASSIS Go to: Insert > Reference Geometry > Plane Select the MIDPLANE CHASSIS. Change the Offset Distance

into 165 mm.

Ensure that the offset is directed to the front. If not, click “Reverse direction” Click OK

Select the new Plane4 and create a new sketch Draw the sketch as shown in the picture and detail.

Detail

Create an extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change

: Midplane into 10 mm

Click OK | Page

Create a fillet Select the green edge as shown in the picture. Go to: Insert > Features > Fillet/Round

> 20 mm

Click OK

Create fillets at the edges of Extrude7 Select the green edges and faces as shown in the picture. Go to: Insert > Features > Fillet/Round

> 20 mm

Click OK

Mirror Extrude7, Fillet4 and Fillet5 Go to: Insert > Pattern/Mirror > Mirror Mirror Face/Plane

: MIDPLANE CHASSIS

Select the “Features to Mirror” option Features to Mirror

: Extrude7, Fillet4 and Fillet5

Click OK

Select the green surface of Mirror2 and create the sketch as shown in the picture

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Create a thin extrude Go to: Insert > Boss/Base > Extrude Direction 1 Change

: Blind into: 40 mm

Select the Thin Feature option. Direction: Midplane Change

into: 8 mm

Click OK

Create a fillet Select the green edges as shown in the picture. Go to: Insert > Features > Fillet/Round

> 20 mm

Click OK

Create fillets on Extrude1, Extrude2, Extrude3, Extrude4, Extrude-Thin1 Select the three green edges as shown in the picture. SolidWorks automatically selects the other edges of these corners. Those are marked in yellow. Go to: Insert > Features > Fillet/Round

> 3 mm

Click OK | Page

Select the green surface of Extrude-Thin1 and create the sketch as shown in the picture

Create an extruded cut Go to: Insert > Cut > Extrude Direction 1

: Trough All

Click OK

Create a new plane parallel at the BOTTOMPLANE CHASSIS Go to: Insert > Reference Geometry > Plane Select the BOTTOMPLANE CHASSIS. Change the Offset Distance

into 308 mm.

Ensure that the offset is directed to above. If not, click “Reverse direction” Click OK

This plane will later be used in the assembly to fix the fuel tank.

Change the name of the new Plane5 Double click on Plane5 in the feature tree. Change the name into: BOTTOMPLANE FUEL TANK CHASSIS | Page

Hide

all planes and sketches except:

-

MIDPLANE CHASSIS FRONTPLANE CHASSIS BOTTOMPLANE FUEL TANK CHASSIS

Change the color of the chassis: Select “Chassis” in the feature tree > Right click > Feature Properties > Color > Change color > Select the color you like Click OK Save the file with the following name: Chassis

Congratulations, you just finished the Chassis!

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