The Chassis started out this 25.5 pound chunk of aluminum measuring 17x7x2 inches. The final weight of the finished chassis is 2.66 pounds! This page shows the block go down to 5 pounds in 12.5 hours of machining.

I started out by squaring up the block with this giant flycutter.

A close up of how much material this tool can remove.

I used a smaller flycutter to face the sides.

I squared the ends using an endmill.

Next it was time to rough out both sides of the chassis.

First I hogged out all the material on this end, nice pile of chips huh?

Then I hogged out the center to start to form the battery pockets.

Then I hogged the other end, you should see the pile of chips on the floor!

A last cut along the outsides of the battery pockets and the bottom is roughed out.

I used the bandsaw to cut away the excess material to form the wheel wells.

Finishing the outside contour with a 1/2" end mill.

I swiveled the vice to blend these angles with the same tool.

I bored a tooling hole directly on center of the length and width to use for future pickups.

Next I started to rough the top of the chassis by tracing the outline of the pocket to verify my numbers and for a visual reference where to cut.

I milled from the center out, gotta start somewhere?

This picture shows the hogged out top pocket, this Chassis is getting lighter.

I traced the outline of the battery pockets with the endmill and then roughed them out.

This picture shows the first battery pocket roughed out.

This picture shows both of the battery pockets roughed out. At this point the 25.5 lb chunk weighed about 5 lbs.

Previous to this opp I left everything slightly oversized to allow the materials stresses to be relieved. This is where I start to mill to size.

Finishing the battery pockets with a 3/4" end mill.

Here I chamfered the battery pocket edge .030"

In this opp I cut as close to the corner as I could and the rest of the material will be blended later on the Sinker EDM.
(next page)

Here I start to finish the bottom with a flycutter.

I rotated the vise 45 degrees to finish the battery pocket chamfers, these pocket walls are from 1/8" to 3/16" thick.

I tipped the part at an 8.867 degree angle on a sine plate to finish these outside edges of the battery pockets.

I finished the milling off with some radii for the top and bottom sides of the chassis.

There it is, ready to be EDMed! check out the next page to see the Chassis get EDMed!