Photos: Sunrayce 99 - Part 1 of 4 - Making of the 1999 Purdue Solar Car

The chassis

The chassis with the solar array substrate

Our team's computer graphics designer finishing the body molds

Chassis, solar array substrate and front body

Some of the solar array panels

This was what I wore in our clean room. Initially, we experimented with using a conformal coating for the solar array. The conformal coating was similar to clear coat paint. Due to technical issues and time constraints, we ended up using Tefzel. Tefzel was a clear film and it also required a separate clear thin film adhesive. The main advantages of Tefzel were relatively easy to apply, consistent thickness, and doesn't cause cancer in animals. I was the team's solar array project manager.


Initially, we used a room in one of the residence halls, but we were allowed to used it for a limited period of time. So we needed to continue our work elsewhere. We ended up creating a clean room using plastic sheets, a furnace filter, box fan and duct tape. I became the bubble boy.


Inside the bubble clean room. I created a wide squeegee to apply the clear thin film adhesive to the Tefzel and then both of them to the solar panel.


Our team's president schmoozing with the engineering department. Our main driver enjoying the scenery.

A test drive

The front body primed and sanded

The front body finished

Our team's vice-president using the CNC to mill the hub

Unveiling our solar car:










Photos by Adrian Silveanu