Budget/Schedule
Task Dates:
The outline of the project was done from Sept. 25th- Oct. 3rd.
The introduction of the project was done by Oct. 4th.
The Methods of the project was done from Sept. 25th- Dec. 11th.
The Analyses of the project was done from Sept. 25th- Nov. 30th. *The analyses will be edited/corrected throughout the rest of the project (around May)
The Discussion of the project was done from Sept. 25th- May. *3rd. The discussion will be completed by the end of the project due date.
The Parts and Budget of the project was done from Nov. 5th- Nov. 30th.
The Drawings of the project will be done by the due date. A rough or first rendering of the drawings will be done by Dec. 11th but, the drawings will change as the design is modified.
The Schedule of the project was done from Sept. 25th- Dec. 5th. The schedule will change as issues come up. A reference for the project timeline will be done by the end of winter quarter.
Deliverables/Milestones:
Milestones are having the material list, budget costs, analyses, design drawings, and the 5 individual hardtop pieces made. The final milestone would be assembling the pieces on the jeep.
The deliverables are having a product that can handle a 400 lb. point load, is waterproof, has a noise reduction value that is at least 15% less than a soft top, and a product that has a heat loss reduction of 20%.
Estimated Total Project Time:
The estimated time for this project is approximately 280 hours. The actual time for the project will not be known until the product is made. Based on the documentation and proposal sections the overall time estimated is close to the actual time spent on the sections/assignments.
List of the parts needed:
S-Glass Fiberglass, Epoxy Resin, Foam Core, Release Fabric, Breathing Material, Brushes/Rollers, Cutters/Shears, Sanding Material, Vacuum Bagging, Tape, Paint, Square Tubing, Rear Window, Side Windows, Bolts/Screws, Plastic Material, Insulation foam.
Part Suppliers:
The S-Glass (*extra), Epoxy Resin, Square Tubing and Foam Core will be purchased on Aircraft Spruce. The Sanding Material (sandpaper) and Insulation Foam will be purchased at the Home Depot. The Rear and Side windows will be purchased on eBay. The Paint used in this project will be purchased on Amazon.
The parts that will be supplied by CWU are: The release fabric, *Fiberglass, Cutters/Shears, Vacuum Bagging Pump, Plastic Material, Tape and Breather Material. By having the opportunity to use these supplies an approximate sum of $400 will be saved. This is without the cost of purchasing a Vacuum Bagging Pump/Parts that costs $467.50 for a basic setup. Having access to these resources cuts the cost of the project in half.
Substantive Costs: The Epoxy Resin, Square Tubing, Rear and Side Windows. These three items add up to roughly $900. These items make up the majority of the cost for the project.
Labor, outsourcing rates & estimate costs:
Labor:
The work done will be done my me so there are no labor costs.
Estimate total project cost:
$1194. Depending on the quantity of material that will be provided/available to use from the donating parties this value can change.
Funding Source(s):
CWU lab resources, Family, Myself.
Estimate total project cost:
There were three ways that money was saved. In order to decrease the total cost, the tubular frame for the side panels was changed and the rear window option was changed. Choosing a standard size of square tubing and lowering the safety factor from 4 to 2.2, decreased the cost by $162.75. Changing from an original rear window to a window made of polycarbonate decreased the cost by $240. These two changes decreased the estimated cost by 35%.
The last item or items that decreased the total cost of the project were the purchases of the side windows. The side windows cost a total of $70 on craigslist. The cheapest options online were an average of $90 for a single side window. By locating these items on craigslist, $110 or 9% was saved.
There were two items that increased the cost of the project. These are the foam option that were chosen for the construction of the panels. The cost of the foam core for the roof panels was estimated to be $88.94, the actual cost was $142.01. The reason for the increase in cost for the foam core was that the cost of shipping was $40. The other item that increased the cost of the project was the change from using insulation foam in the side panels to expanding foam. The cost of the insulation foam was estimated to be $5.98. The expanding foam cost was $53.94. While this is an increase in cost, the time to create the panels will decrease significantly. These two items increased the estimated cost for the foam by 11%.
Other minor increases or decreases to the total cost of the project were due to not adding tax costs. Overall, 33% of the budget was decreased.
The schedule for Spring Quarter comprises of purchasing the necessary parts required to construct the panels and constructing the panels by March *7th. The estimated time required to complete each individual panel was assessed to take an average of 5-6 hours per panel. That would make for a total time of 29.5 hours to complete the panels. So far, the top front and top rear panels have taken that much time alone. The reason for the panels taking a significant amount of time longer than the estimated time is due to the lack of experience working with complicated composite layups. The time estimated was based on working with simple layups. To keep the construction of the panels on schedule, time to work on the panels was increased on the weekend(s) to keep up with the deadlines.
One additional part that was added to the project was the header bar that was used in the construction of the top front panel. This part added a total of 5.3 hours to the project. By using this part, the time to construct the top front panel was most likely decreased. By incorporating a previously designed header bar, one less design for the panels was needed. To shape the foam for a new header bar would have taken at least two to three hours alone.
One major change in the schedule that could have been made to simplify the manufacturing of the panels was, creating all the outside shells before completing a single shell. Due to the structure of the class, an individual had to have one completed part every two weeks. With five panels, the thought was that a panel could be completed every two weeks and the project would be completed on time. This created issues in the long run. By completing a panel, the following panels had to fit perfect with any mistake made with the completed panel. For instance, with a 1-inch thick panel, a bow had to be added to the panel in order to clear the roll bar cage in the Jeep. The thought was that by adding the bow to the Top Front Panel, (the panel that was completed first) the rest of the panels would just match up to it. The problem was that the bow could have had a smaller radius and that mistake was not caught until the side panels were made. While the final product still matched up well, it could have come out more aesthetically pleasing if all the outside shells were made prior to completing a panel. One other thing is that, by completing all the shells prior to starting the interior layups, the shells could have been cleco fastened together and cut to the correct dimensions instantly. By not doing so, there was a lot of wasted time remeasuring the panels to ensure they matched up perfectly.
