How to assemble a Formula One car

[fasteddy]

How to assemble a Formula One car - Part One
 
 
12 February 2007
 
Have you ever complained about how much mechanics charge when they service your car? With the hourly rate so high and with even the smallest fault often taking far longer to fix than you?d imagined, the answer is more than likely a resounding yes. Now imagine how big the bill would be if your car needed to be completely re-assembled - with more than a week?s labour involved, undoubtedly in most cases you?d be better off buying a new car!

In Formula One racing, however, cars have to be routinely rebuilt from scratch at the track in next to no time at all. This will often take place when chassis arrive by air for flyaway Grands Prix - and then there are always those unfortunate incidents during practice sessions, which force mechanics to compete in their own race against time to repair a damaged car. Here?s our step-by-step guide to the process?

Part One - Nude chassis fitting
To begin with the mechanics will take a bare chassis, pre-painted in the team?s livery but without the sponsorship stickers, and fit all the required wiring. With all the car?s sensors, electrovalves and connectors requiring a cable each, it is a huge task. In all, at least 70 separate elements - and several hundred metres of cabling - are fitted to the chassis during this initial stage of the assembly process.

The pedals are then connected to the brake hydraulics, before the seat is lowered into place and fitted. With the rubber fuel tank and safety systems - including extinguisher - pre-assembled in the chassis back in the factory, fuel flaps and fillers are then bolted onto the chassis.

This first phase is one of the most critical and every part is double-checked by the mechanics. Cables which have been improperly fitted could easily be destroyed by heat and lead to retirement in the race. Furthermore, it is essential nothing moves inside the tub. A small bolt or a free cable could easily get stuck under a brake pedal and pose serious safety risks, while any unregulated movement in the fuel tank fillers could cause leakage, or worse still, friction - potentially leading to sparks and hence fire - during refuelling.

This initial part of the assembly process takes about two and a half hours. Make sure to check back throughout the week for the additional stages.
 
 

[fasteddy]

How to assemble a Formula One car - Part Two
 
 
Front suspension and brakes
 
13 February 2007
 
During the second stage of the assembly process, the mechanics fit the front suspension to the chassis. Those elements inside the chassis, including torsion bars, dampers, anti-roll bars and rockers are attached first, prior to the positioning of the steering column and rack and pinion assembly.

Brake pumps are then added to the front of the chassis and their hydraulic cables inserted, before the suspension wishbones are connected. The lower suspension is attached first to the keel or mounting under the tub. The upper suspension is then added, complete with steering links, which are subsequently connected to the steering column inside the chassis.

Next the hydraulic cables for the brakes are passed through the upper wishbones, before the upright struts are put in place. Brake discs, calipers and wheel hubs are then fitted, ahead of a thorough check of all the connections.

This second step takes approximately one and a half hours.
 
 

[fasteddy]

How to assemble a Formula One car - Part Three
 
 
Powertrain, rear suspension and rear wing assembly
 
14 February 2007
 
The car?s powertrain (engine and transmission), rear suspension and rear wing usually appear to be a complete, pre-assembled structure, along with the engine radiators. In reality they come together in at least four separate stages.

The initial operation is to attach all the ancillaries to the engine. Most notable amongst these are the oil and engine radiators, which are subsequently pressurised. The transmission is then connected to the engine, complete with all the hydraulics needed to make gear changes, and the gearbox is filled with lubricant.

At this stage drive shafts and rear suspension elements are added. The suspension wishbones, uprights and brakes are attached following the same procedure used for the front suspension, followed by the dampers and torsion bars, which are attached and inserted into the gearbox casing. After all the hydraulic and electrical connections are fixed and checked, the rear wing is fitted. A further check of all these elements will be carried out again during final tests.

Overall, to complete the fitting operations described above takes just under two hours. On top of that however must be added the time needed to physically connect the powertrain assembly to the chassis. This involves bolting the engine to the chassis mountings, attaching the fuel lines and electrical wiring between the chassis and engine, and positioning the radiators on either the side of the monocoque. The air scoop is also placed on the engine filter box and connected to the chassis at this stage. This whole process takes an additional 45 minutes.
 

[fasteddy]

How to assemble a Formula One car - Part Four
 
 
Nose cone, undertray and bodywork
 
15 February 2007
 
The final stage may at first sight look the simplest, but is actually far from straightforward. Before the undertray is bolted to the underside of the chassis, all the systems which have already been fitted are double-checked.

In particular, the brake system is tested for pressure and any trapped air bubbles purged. Next, all the electrical cables are checked to ensure all the connectors are linked and that all functions are operating correctly. This test is carried out with engine running and the gear change sequence is checked at the same time.

Everything is then checked for potential fluid leaks, before the car?s lower bodywork is fitted. Once any required ballast has been added - this is mounted close to the under-chassis splitter - the undertray is attached. This is bolted under the chassis and connected to a series of tiny links which maintain its rigidity. With the undertray in place, the wooden or carbon fibre skid block is fitted. Barge boards are then attached, both in front of the sidepods and under the front section of the chassis.

Next, the car?s wheels and tyres - covered in tyre warmers - are attached and the tyre pressures checked. The nose cone is then fitted and the front wing profile angle is tested and balanced with the rear wing?s setting. The engine is then started up before mechanics check on its various temperature levels. The car is now ready to go out on the track.

The last stage takes approximately one hour to complete.

In all, it takes a crew of mechanics just under eight hours to completely rebuild a Formula One car. Discount the time it takes to assemble a powertrain and that drops to just under six hours - no doubt much less than it would take your local mechanic take to rebuild your road car!