Skills Used: SOLIDWORKS, Finite Element Analysis, Problem Solving
Project Dates: 2021-Present
Additional Documentation Available: Yes, CAD models
Project Description:
I wanted to build “Rock Sliders” for my FJ40. These are meant to provide protection to the outer lower body when driving over large rocks and must be able to take hard impacts. The challenge here was coming up with something that was easy to fabricate at home and mounted in such a way as to allow the exhaust pipe to travel through it, as the exhaust system is mounted outside of the frame rails (not enough room inside).
I designed a relatively simple to fabricate rock slider that would allow the exhaust to go through it using readily available steel. The design utilized the factory body mounts in the front (right side in the figure). I then performed FEA on the setup using SOLIDWORKS and with assumptions of most of the weight of the vehicle in a worst-case impact right in the middle of the slider. Ideally, the slider would be strong enough as to be able to lift one side of the vehicle from any point along its length.
Project Results:
Unfortunately, the FEA showed that it could not take the load applied without yielding. Even after several design changes and much additional metal, it still yields. Because of this and other more pressing issues coming up, this project has been shelved for the time being.
