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Chassis

Open a new part with model units set to

millimeters.

Select the three planes in the feature tree

and make them visible by clicking on the

glasses.

Change the name of the Top Plane

Double click on the Top Plane in the

feature tree.

Change the name into: BOTTOMPLANE CHASSIS

Change the name of the Front Plane

Double click on the Front Plane in thefeature tree.

Change the name into: MIDPLANE CHASSIS

Select the MIDPLANE CHASSIS and create a sketch

by clicking on the 2D Sketch icon

Insert a sketch underlay

For this part of the chopper we use a hand made

sketch as underlay to simplify the design processof the chassis.

Go to: Tools > Sketch Tools > Sketch Picture

Select Chopper Underlay.Jpeg

Click: open

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Change the position of the underlay to ensure that the underside

of the chassis is equal with the BOTTOMPLANE CHASSIS.

Change the dimensions of and as shown in the picture.

Click OK

Change the name of Sketch1

Double click on Sketch1 in the feature tree.Change the name into: CHASSIS UNDERLAY

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Select the MIDPLANE CHASSIS and create a new sketch

Hide the underlay if this is appropriate

Click on CHASSISUNDERLAY in the feature tree and hide this by clicking on the

glasses. Use the underlay whenever you want.

Draw the sketch as shown in the picture.

Close the sketch.

Select the MIDPLANE CHASSIS again and create another sketch


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Hide the underlay if this is appropriate

Close the sketch.

Select the BOTTOMPLANE CHASSIS and create a new sketch


Close the sketch.

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Create a projected curve

Go to:Insert > Curve > Projected

Selections : Sketch2 and Sketch3

The yellow line is a combinationof Sketch2 and Sketch3.

Click OK

Create a sweep

Go to:Insert > Boss/Base > Sweep

Profile : Select the green Sketch1

Path : Select the pink Curve1

Click OK

Mirror Sweep1

Go to: Insert > Pattern/Mirror > Mirror

Mirror Face/Plane : MIDPLANE CHASSIS

Select the Features to Mirror option

Features to Mirror : Sweep1

Click OK

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Select the Right Plane and create

a new sketch


Create an extrude

Go to: Insert > Boss/Base > Extrude

Direction 1 : Blind

Ensure that the offset is directed

outwards as shown in the picture.

If not, click Reverse direction

Change into 22 mm

Click OK

Select the green surface as shown

in the picture and create a new sketch


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Create an extruded cut

Go to: Insert > Cut > Extrude

Direction 1 : Up To Next

Click OK

Create a chamfer

Go to: Insert > Features > Chamfer

Select the green edge as shown in the picture.

Select the Distance distance option.

Change into: 90 mm

Change into: 44 mm

Click OK

Create nine fillets

Select the green edges as shown in the picture.

Go to: Insert > Features > Fillet/Round > 25 mm

Click OK

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Create two large fillets

Select the green edges as shown in the picture.


Click OK

Create a new plane parallel at the MIDPLANE CHASSIS

Go to: Insert > Reference Geometry > Plane

Select the MIDPLANE CHASSIS

Select the green Vertex point of Fillet1 as shown

in the picture

Click OK

Select the new Plane1 and create a new sketch

Draw the green vertical construction line. Fix the construction

line at the corners of Fillet1 as shown in the picture and detail.

Detail

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Show the underlay if this is appropriate

Draw the spline as shown in the picture.

Fix the right side of the spline at the midpoint of the vertical construction line and

make the spline tangent at the horizontal construction line as shown in the detail.

Detail

Close the sketch.

Select the green surface of Extrude1 and create a new sketch

Draw the sketch and make the circle concentric with the green radius asshown in the picture.

Close the sketch.

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Create a sweep



Path : Select the pink Sketch6

Click OK

Select Plane1 and create a new sketch


Close the sketch.

Select the green surface of Extrude1

and create a new sketch

Draw the sketch and add a concentric

relation with the green arc as shown in the

picture.

Close the sketch.

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Create a sweep




Click OK

TIP: An underlay could help you to design your 3D models in the correct dimensions

and proportions. This could be very helpful during the design process of a product.

Before you start with 3D modeling, we recommend you to sketch the concept by

hand first. You could also use a photo as underlay and avoid a lot wasted time and

frustration. Think twice, do once!

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Select Plane1 and create

a new sketch

Draw the sketch as shown

in the picture.

Create an extrude


Direction 1 : Midplane

Change into 44 mm

Click OK

Select the green surface of Extrude3

and create a new sketch


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Create an extrude


Direction 1 : Blind

Ensure that the offset is directed

outwards as shown in the picture.


Change into 223 mm

Click OK

Create a dome

Go to: Insert > Feature > Dome

Select the green face of Extrude3.

Change the Distance into 10 mm

Dont select the Elliptical dome option

Click OK


Show the underlay if this is appropriate.


Close the sketch.

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Create a new plane parallel at the Right Plane


Select the Right Plane

Select the green Vertex point of Sketch12

as shown in the picture.

Click OK

Change the name of Plane2

Double click on the new Plane2 in thefeature tree.

Change the name in: FRONTPLANE CHASSIS

Select the FRONTPLANE CHASSIS and create

a new sketch


Make the midpoints of the circles coincident

at Sketch12.

Close the sketch.

Create a sweep




Click OK

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Select the MIDPLANE CHASSIS andcreate a new sketch




Direction 1 : Mid Plane

Change into 60 mm

Click OK

Create a new plane parallel at the BOTTOMPLANE CHASSIS


Select the BOTTOMPLANE CHASSIS.

Change the Offset Distance into 185mm.

Ensure that the offset is directed to above.


Click OK

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Draw the sketch as shown in the picture and detail.

Ensure that the horizontal construction line is fixed at the origin.

Close the sketch. Detail



Show the underlay if this is appropriate.

Ensure that the spline is fixed at the middle of the circle of Sweep1.

Close the sketch.

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Create a sweep




Click OK



Create a revolved cut

Go to: Insert > Cut > Revolve

Axis of revolution : Select the green line


Click OK

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Detail

Create a revolve

Go to:Insert > Boss/Base > Revolve

Axis of revolution : Select the green construction line


Click OK

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Create an extrude



Change into 340 mm

Click OK

Create fillets on Revolve1 and Extrude6

Select the green surfaces of Revolve1 and Extrude6 as shown in the picture.


Click OK

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Create a new plane parallel at the MIDPLANE CHASSIS


Select the MIDPLANE CHASSIS.

Change the Offset Distance into 165 mm.

Ensure that the offset is directed to the front.


Click OK



Detail

Create an extrude



Change into 10 mm

Click OK

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Create a fillet

Select the green edge as shown in the picture.

Go to: Insert > Features >

Fillet/Round > 20 mm

Click OK

Create fillets at the edges of Extrude7

Select the green edges and faces




Click OK

Mirror Extrude7, Fillet4 and Fillet5

Go to: Insert > Pattern/Mirror > Mirror

Mirror Face/Plane : MIDPLANE CHASSIS

Select the Features to Mirror option

Features to Mirror : Extrude7, Fillet4 and Fillet5

Click OK

Select the green surface of Mirror2 and create

the sketch as shown in the picture

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Create a thin extrude


Direction 1 : Blind

Change into: 40 mm

Select the Thin Feature option.

Direction: Midplane

Change into: 8 mm

Click OK

Create a fillet

Select the green edges




Click OK

Create fillets on Extrude1, Extrude2, Extrude3, Extrude4, Extrude-Thin1

Select the three green edges as shown in the picture.

SolidWorks automatically selects the other edges of these corners.

Those are marked in yellow.


Click OK

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Select the green surface of Extrude-Thin1 and create the sketch as

shown in the picture



Direction 1 : Trough All

Click OK

Create a new plane parallel at the BOTTOMPLANE CHASSIS


Select the BOTTOMPLANE CHASSIS.

Change the Offset Distance into 308 mm.

Ensure that the offset is directed to above.


Click OK

This plane will later be used in the assembly

to fix the fuel tank.

Change the name of the new Plane5

Double click on Plane5 in the feature tree.

Change the name into: BOTTOMPLANE FUEL TANK CHASSIS

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Hide all planes and sketches except:

- MIDPLANE CHASSIS

- FRONTPLANE CHASSIS

-

BOTTOMPLANE FUEL TANK CHASSIS

Change the color of the chassis:

Select Chassis in the feature tree > Right click > Feature Properties > Color >

Change color > Select the color you like

Click OK

Save the file with the following name: Chassis

Congratulations, you just finished the Chassis!

11. chassis

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