STUDENT PROJECTS

Viking 21, Electric CNG Hybrid vehicle The Viking 21 competed in the first Solar Electric Challenge for Pikes Peak. It won overall and was first in its class.

Viking 23, Gasoline Electric hybrid Two Unique Mobility brushless D.C. motors driving the front wheels through a gearbox. 11 kW hours of SAFT NiCad batteries charged by either the solar cells or household current. 70 miles in zero emission mode at city speeds and approximately 400 miles at highway speeds. Daihatsu, 993cc, 3 cylinder fuel injected single overhead cam, fueled by reformulated gasoline. Carbon fiber monocoque 1988 -- American Tour de Sol: First Place DOE Hybrid Class Most Efficient Hybrid

FORMULA SAE IS A DESIGN COMPETITION FOR ENGINEERING COLLEGES AND STUDENTS IN 1994-96, THE WWU TEAM PREPARED A CARBON FRAMED CAR WITH A PRORIETARY V8 AND GEARBOX. I WAS INVOLVED WITH DESIGN ASPECTS OF EACH COMPONENT.

SPARROW PROJECT 1996-1998

The Corbin Sparrow electric vehicle. It lived a short and troubled life, and I felt the vehicle was rushed into production without some safety testing complete, so I left the project.

I developed the tooling and final body shell (but not the styling!) for the Sparrow. This includes glass, door and window drop. I also designed the suspension, Braking, drive system, and everything else to be road-worthy.

The rear swing arm and motor drive assembly I designed and developed.

Toyota CART Indycar, 1998-2000

The Toyota Eagle was designed and built in Southern California at Dan Gurneys AAR facility.

The Eagle chassis under construction

I helped engineer, package, and develop the composite chassis and later with vehicle dynamic developments.

THE AAR 7 POST (4 WHEEL AND 3 DOWNFORCE LOAD) CHASSIS TEST SIMULATOR ABOVE. BELOW THE AAR 40% SCALE ROLLING ROAD WIND TUNNEL AND MODEL SHOP

Above is the AAR Water drag tank, used to check flow patterns behind a moving vehicle. On the right: tooling models were all cut from epoxy on 5 axis mills In the middle: TEC Autoclave of 9x18, 800 F, 200 psi nitrogen purged. Below is a company photo from 1999 with Dan Gurney and some of the racing cars we designed and built

Ford Fortynine Concept car. Debut at the 2000 NAIAS show. Voted Best Concept of Show

FINISHED CAR ABOVE

CLAY MODEL TAKING FINAL SHAPE ABOVE

I ENGINEERED THE CHASSIS AND BODY FOR THE FORTYNINE AS WELL AS PROGRAM MANAGED THE DESIGN AND BUILD OF THE RUNNING CAR

More images of the Fortynine in progress and complete. Note the all flush glass and that the doorglass was a full drop. The car was fully operational and required to be capable of 100mph for press use.

Below are examples of concept vehicles contracted to the Ford Ctek studio. I engineered aspects or entire designs of several of these as well as other vehicles not shown here

A clay concept for client with me in drivers seat.

An SUV concept for Mitsubishi

A functional movie vehicle for Lexus

A concept design for Panoz

Testing and development

Chief Road Test Engineer, North America

Road testing and on-vehicle development at the NA Brembo lab

Road testing, examples of me pushing the car for development as the Chief of road testing in North America

A CAD-CAE sample of a prototype caliper I engineered

My brief time with the short-lived California Prodrive office included projects in CAD-CAE development, body-in-white development, and suspension development, which I cannot show here due to their on-going and private nature. So here I show examples of the Top level competition developments of Prodrive during the time I was there.

TRW Japan, in Yokohama. This is the newly constructed Technical Center including complete vehicle test and development capability. I Lead Development and Application engineering for many JOEM chassis system projects.

Cross Member Modules Rack and pinion steering gear, frame assembly, knuckle

Actuation Pedal - Box Brake master cylinder, booster, pedal box, accelerator, brake pedal, clutch pedal and clutch master cylinder (manual transmission only)

Brake Modules Braking disc, caliper assembly, hub and bearing assembly, knuckle assembly

Axle Modules Axle, drum brake, drum bearing, sensors, shock/strut, springs, parking brake cables

Corner Modules Brake module, strut, knuckle assembly

FISKER AUTOMOTIVE

Developing the Fisker Karma. Managing the ER&D fleet for DV / PV.

Road and closed course vehicle testing and validation

Packaging studies with proof of concept modeling in rapid prototype plastic.

Following are examples of CAD-CAE models in various stages of progress. All are my original work.
Below is a mid engined sports car packaging design, utilizing a carbon composite chassis

A High performance vehicle corner design including all components from the wheel inboard.

A Concept chassis and suspension-packaging design with steel space frame

Initial packaging and design of concept with major chassis components in location

Space frame tube chassis, suspension systems with resolved geometries

More Chassis design studies

Left and below is an extruded aluminum section lightweight sports car chassis study.