Harness Mounts and Jigs
Machined 4 pairs of harness mounts and designed positioning jigs to ensure a FSAE-compliant driver harness.
What?
FSAE rules mandate a 5-point harness with specific shoulder and lap mount locations for driver safety
4 pairs of AISI 1020 steel mounts needed to be structurally welded to the primary chassis tubes with identical positioning on each side
How?
Created technical drawings and a DXF to waterjet steel blanks. I then used the bandsaw to make an angled cut so that each mount could fit on the side of a square chassis tube
Designed a 2-part split jig in SolidWorks that wrapped around the chassis tubes and bolted together. This would constrain all 6 DOF to hold the mounts in place during tack welding
Results?
The mounts were TIG welded to the chassis and are capable of withstanding 15kN of force from the harness
Mounts held the driver securely and passed technical inspection at FSAE competition, confirming full rules compliance
