Project Eclipse: Feb 16 to 23 Update

Back after Family day, Car Club is working hard on preparing several small components to assemble our Spirit Car in time for its unveiling at the School Carnival in May...


The last "big" issue on our list for the audio/video system is creating the "mid-frame," a middle structure that serves as both an amplifier rack for the sound system, but also a helps blend the shape of the subwoofer enclosure with the middle section of the Eclipse. Last year, we ditched the rear seats in order to make more space for the TV and amplifiers. Now, the trick is trying to use that space both practically and esthetically.

First, we designed and built a wedged shaped panel that would sit in the back seat area just in front of the TV...but it didn't seem to complement the curved nature of the sub box...

So we removed it and headed back to the drawing board for some other ideas on what panel would create the mid-frame...

In the meantime, Car Club students tended to several other jobs in and around the car.
Two senior students helped secure the TV support bracket onto the chassis, as it tended to wobble when the TV was motorized:





SHSM students helped diagnose and narrow down a raised panel on the rear hatch cover which was not letting the hatch close properly over the sub box. An easy fix! That student cut out the raised portion and installed a flush panel which will soon be fibreglassed or carpeted over to give uniformity to the hatch.





Two more students worked on enlarging the factory speaker brackets for the rear 6x9s. The original 6 inch speakers will be replaced with much more powerful Kicker Audio speakers.





The following week, we finalized an idea for the mid-frame. A flatter panel was to be constructed, recessed under the TV and stretch across the former rear seat area.
But in order to create this panel, we had the tedious job of creating and carpeting a rear seat area cover, to hide the fuel tank access plate and body wiring.
Additionally, the entire linear actuator system had to be moved rearward and bolted tightly so as to make space for the new carpeted floor plate.



With these adjustments made, and the actuator travel reset, we could install the new mid-frame.
Another couple of students removed, cleaned and painted the rear speaker grilles, to match the school's colours.

As a nice touch, Car Club's senior students helped install and carpet last week's flying frame with large new "B R" initials.







We previously had contemplated smaller initials, but the new bigger CNC-made initials have a better look!



Next week, the mid-frame will also be carpeted before we lay out the entire electrical system for the Eclipse's audio and sound components.

We decided to extend the mid-frame's top banner for a special component that's sure to get attention from onlookers...



With the mid-frame and flying frame nearly complete, we decided to create a special light-up sign that will be visible at night between the front seats. After digitally carving a recessed front panel and some painted acrylic in Mr. Mule's room, we will get out the Arduino boards and devise a way to create a fading red BR sign for the car...



Our prototype will soon be ready for testing and carpeting before it is installed in the car.



Join us on our next update where we tackle final carpeting and construction of the tail panel where our wireless keyboard will sit.

We are switching gears in room 114, and Mr. DaSilva is proud to be teaching the kids of Car Club and SHSM how to take something old and give it new life again!

See you next time!

Project Eclipse: Feb 2 to Feb 9 Update

Well, after semester one exams, the students of BR are back at it in semester two!

After a brief break to study for and write their exams, Car Club and SHSM students are back in room 114 to continue our rebuild of the BR Spirit Car.

We are making some excellent progress with Project Eclipse and are right on track towards our scheduled unveiling date of May 18th, our annual school carnival.

Over the last two weeks, Car Club students have helped finalize details of the massive trunk-spanning subwoofer box. By taking various ideas from Mr. Mule's design tech class on speaker placement, we decided to build a sturdy sealed sub box from the ground up that would house four ten inch Kicker subs. With the final steps underway, a few senior students helped complete the top portion of the fibreglass enclosure before adding some bondo and putty to smooth out any rough spots and help seal the box.

Once smoothed, we decided to carpet wrap the heavily contoured box in order to cover any construction flaws and give it that classic upholstered look. The wrap process was slow and tedious, leaving a few spots behind that one piece of carpet could not cover.

But with a careful hand and a razor's edge, Mr. Da Silva and the students helped wrap the affected area with minimal flaw to the seams in the wrap.

The finished box looks much better and once the subs are in place, the unit looks ready for its new home in the Eclipse.

When the system was tested a couple of weeks ago, we noticed a few air leaks around the base of the subs as well as at the holes where the speakers were connected. 

Time to fix that, as buzzing much degrades the speaker's sound quality...

First we drilled out the initial speaker wire through holes and replaced them with form fitted spring terminals...

Now the sub box has the proper wire terminals for connecting the subs to the high power 1200 watt monoblock amplifier.

While some Car Club students readied the subs for securing into the sub box, another student crawled into the back seat area of the Eclipse and secured the remaining pivot bracket below the TV monitor actuator assembly. Now the TV will rise and retract to the correct angles.

Back at the sub box area, two senior students prepared the wiring and spade connectors for the subs, while two junior level members installed new foam sealing gaskets around the back of the sub baskets so that they will not leak air during their operation in the air tight box. 

The subs have been wired in a way as to fall within the amp's resistance load. This way, we have optimum sound, but do not overrun the amp's power output.

Once back in the trunk, the carpeted box fits quite snugly in its new home and with the TV motorized out of the trunk, the vehicle looks ready for any special event at BR!

...but we are far from finished, so we focus next on building a "flying frame" to encompass the TV when it is in the fully retracted position. In order to build a sturdy unit that can withstand the vibrations of the subs, we welded steel ribs that attached to the old rear seat supports. From there, we extended wood brackets and secured them to the contoured wings that we cut on the band saw.

With a cross piece in place, the flying frame is quite rigid, and will be carpeted once the rest of the mid-section (the panel that holds the twin amplifiers) is constructed.

The TV now has a defined base which to retract in and out of.

By the end of this week's car club, we rig an amp and battery to the subs and give it a dry run using a music app on the vehicle's on-board tablet. 

Although the Kicker sub amplifier has over 1000 watts of power, we don't want to resonate the TV to its destruction. However, Mr. Da Silva and the students were pleased to find that, at half power, the sound system pumped clean sound throughout the vehicle...and had enough thump to vibrate the rear-view mirror!

With our work closing in on the completion of the sound system on the BR Spirit Car, we are looking forward to the day when we can roll out the mighty Eclipse and park it at school events, throw open the door, crank on some tunes and enjoy the day!

It won't be long before Project Eclipse is complete...Join us at the finish line and help celebrate the shining achievements of Student Success at BR!