Testing

SIDE DOOR STRENGTH TEST – 15.05.2012

Scope

The function of this test is to specify strength, stiffness and requirements for side doors of Rod Bods Downunder Fiberglass automotive body’s which can be used for occupant access therefore reducing intrusion into the passenger compartment as a result of side impact.

(As per the intent of Australian Design Rule 29/00).

Although this Test has been carried out on a Rod Bods Downunder 1932 3 Window Coupe Body, the following range of Rod Bods Downunder bodies, 1932 Tudor, 1934 3 Window Coupe and 1934 Tudor, have the same steel reinforcement and approximate door size of the 1932 3 Window Body, including A and B Pillar structure.

Therefore it is my belief that they would have the same performance results if the same test was carried out on each separate Body Style.

Test Equipment

Test Body - 1932 Three Window Coupe

Load Cell – PT 200m Low Profile Universal LPCH 10tonne (1234000)

Calibrated: 05.04.2012

5 ton hydraulic ram

Loading Device - Semicylinder 305 mm in diameter, with edge radial of 12 mm

Pre Test

The 1932 Three Window Coupe Body was bolted to a rigid metal jig using all the body mounts and 7/16 UNF bolts as if mounting the body to an original chassis. The test body had no seat fitted.

The loading device consisting of a substantially rigid semicylinder 305 mm in diameter, with edge radial of 12 mm was connected to a 5 ton hydraulic ram.

The ram lies in a metal cradle attached to the rigid metal jig. A load cell rests at the opposite end to the loading device agents a solid shoulder welded to the rigid jig. Two metal tubes were added to the rear of the load device to minimise rotation during test.

The loading device was aligned with the centre of the door. The bottom edge of the loading device measured 127mm above the bottom edge of the door and the top of the loading device was more than 12mm above the bottom edge of the window opening

Body measurements before test:

A Pillar to B pillar at swage line: 990mm

A Pillar to A Pillar across body at swage line: 1230mm

B Pillar to B Pillar across body at swage line: 1435mm

Post test

Body measurements after test:

A Pillar to B pillar at swage line: 990mm

A Pillar to A Pillar across body at swage line: 1230mm

B Pillar to B Pillar across body at swage line: 1435mm

Approximately 200mm into the test the outer fibreglass door skin released from the inner door.

The door hinges deflected approximately 10mm without failure.

The steel framework and intrusion bars inside the door deflected with no welds failing, the only metal failure was a small tear in the 1mm plate that lies between the door lock and the fibreglass door shell.

The door lock failed (1989 Ford Laser/Mazda Ute) at 315mm into the test with the rotating locking leaver twisting and breaking the lock.

Conclusion

The door failed after traveling the minimum 310mm required in ADR29 with a peak load of 3030kg. The body had zero deflection to both A and B pillar. As a result from the test performed and the use of the equations in ADR29 (2 times the unladed weight of the Vehicle peak load 3030kg) a vehicle can be built with this body to a maximum tare weight of 1515kg.

With the test performed the strength in RodBods Downunder doors and bodies meet the intent strength of ADR29.

SEAT BELT MOUNT PULL TEST - 15.05.2012

Scope

The function of this test is to validate the strength of Rod Bods Downunder Three (3) point Seat Belt Mounts as supplied in Rod Bods Downunder Three Window & Five Window Coupe Fiberglass automotive bodies.

Although this Test has been carried out on a Rod Bods Downunder 1932 3 Window Coupe Body, it is my belief that if the same test was performed on each of the following Rod Bods Downunder Body Styles, comparable results would be found due to the similar or if not exact steel reinforcement in each of the body styles.

· 1932 5 Window Coupe

· 1934 3 Window Coupe

· 1930 Model A 3 Window Coupe

· 1930 Model A 5 Window Coupe

Test Equipment

Test Body - 1932 Three Window Coupe

Load Cell – PT 200m Low Profile Universal LPCH 10tonne (1234000)

Calibrated: 05.04.2012

5 ton hydraulic ram

Loading Device - 16mm Hi-tensil chain, D shackles, Pulling Devices for sash and lap made as per requirements stated in ADR 5/05.

Test Performed

The test was set-up with the hydraulic ram, connected to a solid framework utilising a pivot bolt, in turn the load cell was screwed directly to the hydraulic ram cylinder.

Conclusion

With the test performed the strength in RodBods Downunder Seat Belt Mounts meet the intent strength of ADR 5/05