Assembly

In my time at Dallara I primarily moved between manufacturing carbon parts and assembling an IR12 show-car as parts came in. This combined experience gave me confidence to under go the challenge of designing and manufacturing an underfloor for my capstone project, now with the skills needed to produce professional level carbon fiber parts

Dallara
Summer 2024

IR12, Road Course Config

Ongoing through my time at Dallara, I and the head of Assembly, Owen Snyder, assembled this IR12 as parts became available. Though this will be a show-car for Dallara, it uses all genuine parts — no stand ins — most having exceeded their legal mileage limit for competition. With the exception of an engine and electronics this car has all the components you would expect to find on a race going Indycar. This was a total kid-in the candy store project for me and I was so grateful to work on a car of this level.

  • L: Car started as a bare monocoque — though different monocoque is shown in image

  • R: First the rear suspension assembly, transmission and engine (in this case stand in frame pictured in blue) are all bolted to the monocoque as one unit. This picture was taken near completion

  • L: Bodywork stripped of old livery, cleaned

  • R: Side impact structure half covered by bodywork, below sits intercooler/radiator housing, “shelves” are for electronic components

  • L: Radiator mounted on the back of housing with zip ties! Yes this is standard practice, not a show car thing… who would have guessed!

  • R: Front Suspension being assembled, control arms in place along with steering race and arms, rockers missing from shocks

  • L: Mechanism for front wing attachment/quick release. Very cool yet simple mechanism, may be used in capstone project for diffuser connection.

  • R: Front wing mounted and mechanism adjusted for fit

  • L: Jack car and reposition stands to mount underfloor

  • R: Front wing uprights assembled and mounted, suspension arms now connected to shocks via rockers

  • L: Interior Seat and Belts installled

  • R: Steering wheel, interior trim, pedal box, fire system

  • On the ground! This is how the car sat at the end of my time at Dallara. Everything was complete with exception of the rear wing and matching the body panels