Master AssemblyHome The SUR25 master assembly brought together all major subsystems into a single top-level model: – Chassis (monocoque + spaceframe) – Vehicle dynamics (suspension, steering) – Ergonomics (cockpit packaging,…
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Assembly & ManufactureHome The aluminium monocoque was produced using a cut-and-fold process, a technique that transforms flat honeycomb sandwich panels into complex 3D structures. Each Larcore A20 panel was CNC-cut…
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Aluminium Monocoque ChassisHome The 2025 chassis was designed as a cut-and-fold aluminium honeycomb monocoque bonded to a steel rear spaceframe. This hybrid structure combined the lightweight stiffness of a monocoque…
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Roll Hoops & Harness BarHome Roll hoops and the harness bar were mounted using reinforced inserts and base plates within the monocoque, designed to meet FSUK rollover protection standards. The…
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Material Testings Home The aluminium honeycomb monocoque was validated against FSUK SES requirements through physical testing. Three-point bending showed panel stiffness above the T45 steel baseline, confirming equivalent flexural performance.…
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Welding & Assembly FixturesHome Custom fixtures were built to ensure accuracy during chassis manufacture. The monocoque was folded and bonded in CNC-cut MDF jigs that controlled panel angles within ±0.5°.…
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Close-out PanelsHome Created carbon fibre panels secured to the lower tubes of the chassis to provide driver protection. These not only serve as safety barriers (guarding against debris, tubing ends,…
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Front GeometryHome Suspension geometry was integrated into the monocoque, with pickups mounted beneath the chassis to accommodate longer lower A-arms. This configuration extended the front-view swing arm length (FVSAL), producing…
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Spaceframe ChassisHome This spaceframe represented the most significant departure from Staffordshire Uni Racing’s previous designs, incorporating major changes in geometry, load paths, and manufacturing detail. Built from T45 steel tubing,…
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