ATL are the safety fuel cell manufacturer of choice for most of the major race car constructors around the world; including possibly all of todays F1 teams.

Damian was able to visit the factory in Milton Keynes this past Christmas period to finalize our cells design and tooling directly with their engineers.

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The next couple of coming months will be very exciting for the project, after committing to production late in 2009, we are now only a month or two away from delivering our first rolling chassis and progressing to our on circuit test phase.  We will be keeping you all well-informed during this period via this facility.

Regards,

Rob Whalan
Director
Oryol Cars Pty Ltd

Currently some final crash structure inclusion panels are being considered before the first complete set is completed – but not far away now.

Please see below, some great quality work by the guys.

Engine Cover

Airbox and Rollover

Chassis Panels...

Chassis (inside the cockpit)

The first chassis has been progressing methodically.  With fitted finished components the welder is reporting unbelievably accurate tolerances.

With qualified welders, all welding is completed to aerospace standards.

Engine Cover 8 (sharp finish)

Final work on body plugs and moulds is well underway.

The work carried out from the initail design concept, aero analysis, surface modelling and now tooling production, has been carried out to the highest exacting standards – standards yet seen in the production of Formula Ford racer.

See below.

Engine Cover 10 (Near completion)

Engine Cover 9 (on the bench)

Engine Cover 5 (slowy and accurately)

Engine Cover 4 (roughing out)

Nose 3 (amazing control)

Nose 1 (cutting out)

They were given a tour of the facility and got to see the 7075T6 front bullhead and engine mount of  Oryol’s prototype P2S10 in production.

The Oryol Cars directors were most impressed with the complexity of the parts which Ferra manufactures for the aerospace industry and the high levels of quality which includes 100% of completed parts being measured in a coordinate measuring machine (CMM).

It’s a credit to them, and also reasuring for both our product and customers, that all work carried out within their facilities is finished to these exacting standards.

Since our visit, some of the following components have been completed;

Engine Mount

We have just taken delivery of the first consignment of  laser cut tubing, so welding of the main chassis can now commence  early next week.

Chassis Tooling Assembly

www.oryol-cars.com

We won’t be on holiday though, from that point we’ll be flat-out with chassis assembly and welding.

Ferra is one of Australia leading specialists in the design, manufacture, assembly and test of aerospace structures and sub-system.  Serving local and overseas defence and aerospace companies, they support customers on development programs, established platforms and provide a wide range of services including spare parts for regional, business and military services.

For Oryol Cars, this represents a massive vote of confidence in our product, processes and values, that a company of Ferra’s standing recognises the work and achievement we have made up until now.

To learn more about Ferra and what they do, refer to Partner Links on the front page.

The contract was awarded after a competitive tender process with a number of suppliers taking part, who all stated their enthusiasm to work on the project.

Thanks to all those for taking part.

We expect model and moulds to be completed within 3 to 4 weeks time from now, with many of our other parts also being machined, fabricated and assembled as we speak, it’s only a matter of weeks before we start seeing the design come together in the physical sense.

CNC Modelling Robot

Russell is one of the best surface modellers around with a lifetimes experience in the discipline, he utilises all the latest and most advanced modelling software available in todays advanced manufacturing environment; we were very lucky to have found Russell and are so glad we did. 

We now have some great rendered pictures depicting just how good the new car should look.  (These are not artistically rendered conceptual drawings, but are actual rendered Computer Aided Design drawings)   

The final look and feel of the car is a combination of aerodynamic CFD analysis and F1 inspired design.  These features combined with G3 continuity of shape and flow give us the fantastic shape we now can see.   

The results show a marked improvement not only in aerodynamics but also in looks against other modern-day Formula Fords.   

There is no doubt that the Oryol P2S10 Formula Ford is going to reinvigorate the look and feel, of Formula Fords, to that of other modern formula racecar designs.   

The red car in Berlin

Front Ground Level

Mirrored Shape

Side - Computational Fluid Dynamics (CFD) analysis

The rapid casting process utilizes wax printed models for one run cast components. 

Casting Pour

Please stay tuned for milestone updates, announcements, and pictures.