VETERAN TECHNICAL INSPECTORS ADVANCED SEMINAR 2015

Seatbelt installation “3-bar adjuster”

Seatbelt installation Step 4 is very frequently overlooked, but simple to identify, and easy to fix. Good Belt passes through rearward slot 3 times

Seatbelt installation- advanced Belt passes through forward slot 3 times Acceptable alternative for 3-bar adjuster used to wrap around frame tubes.  More compact, but more difficult to install.

Seatbelt installation- other types “Light Weight Wrap”- common for anti-sub belts. Belt passes through slot 4 times

Harnesses are a System Acceptable* if tab cross-section area is met if using manufacturer’s hardware and instructions (Don’t forget the cotter pin!)

Driver’s Equipment Balaclava A balaclava which covers the driver’s head, hair and neck, made from acceptable fire resistant material as defined in <>, or a full helmet skirt of acceptable fire resistant material. The balaclava requirement applies to drivers of either gender, with any hair length. (Was “Applies to ALL drivers”.) Eye Protection Impact Resistant goggles or helmet face shield, made from approved impact resistant materials. The face shield supplied with approved helmets (See <> above) meets this requirement. Socks Fire resistant socks made from acceptable fire resistant material as defined in <>, below, that cover the bare skin between the driver’s suit and the boots or shoes. Note: Socks must be Nomex or equivalent. Cotton or wool no longer acceptable.

Gage Proper use of edge radius gage Gage Nose 1 Gage contacts at ‘points’- PASS So far so good, but… Nose 2 Rotate only to 45°, so that bevel edge is vertical.

 Gage is intended to be rotated +/- 45° Proper use of edge radius gage Gage

Edge radius gage- more challenging examples Gage Nose 3 Nose 4 Bottom lip OK if < ~2” from ground (heel height) Gage Nose 5

Edge radius gage- sanity check Practical safety: Would you be concerned if you were standing near this car? Nose 6 Real-world examples aren’t simple. We value your judgement! Consider discussing with fellow inspectors.

Frame structure names Front Hoop Bracing Front Bulkhead Front Bulkhead Supports (3+) Front Roll Hoop Side Impact Structure (3) Main Hoop Bracing Supports (2) Main Roll Hoop Harness Mounting Bar Main Hoop Bracing

Steel tube wall thickness (1” OD, most common).095”.065”.049”

F Frame tube triangulation Basics Multilateral > 3 sides Trilateral F FF (Combination) F FF “Bay”

Frame tube triangulation All bays triangulated

Frame tube triangulation

OK

Frame tube triangulation

Fully triangulated again

Frame tube triangulation

Bottom bays are triangulated. Upper bay is not. (This is OK)

Frame tube triangulation This is the same frame! A real frame has “other” links, on top of the minimum structures. Be sure to confirm which links are the required materials, and which are thinner (weaker.)

Frame tube triangulation Suspension mount puts bending into required structure.

Frame tube triangulation Additional link provides triangulation, OK now. T3.13.7If any item which is outside the envelope of the Primary Structure is attached to the Main Hoop braces, then additional bracing must be added to prevent bending loads in the braces in any rollover attitude.

Safety Wire - sometimes All critical bolt, nuts, and other fasteners on the steering, braking, safety harness, and suspension must be secured from unintentional loosening by the use of positive locking mechanisms. Positive locking mechanisms include: - Correctly installed safety wiring - Cotter pins - Nylon lock nuts - Prevailing torque lock nuts Note: Lock washers and thread locking compounds, e.g. Loctite®, DO NOT meet the positive locking requirement. There must be a minimum of two (2) full threads projecting from any lock nut. There are 4 options! (Safety wire is just one of them)

Safety Wire - sometimes “Through bolt”“Blind screw” - Correctly installed safety wiring - Cotter pins - Nylon lock nuts - Prevailing torque lock nuts - Correctly installed safety wiring - Cotter pins - Nylon lock nuts - Prevailing torque lock nuts

Safety Wire - sometimes “Through bolt” - Correctly installed safety wiring - Cotter pins - Nylon lock nuts - Prevailing torque lock nuts

Safety Wire - sometimes “Blind screw” - Correctly installed safety wiring - Cotter pins - Nylon lock nuts - Prevailing torque lock nuts

Safety Wire - sometimes Other threaded fasteners (ie: spindle nut, wheel nut) - Correctly installed safety wiring - Cotter pins - Nylon lock nuts - Prevailing torque lock nuts

Safety Wire - sometimes Blind screws - Correctly installed safety wiring - Cotter pins - Nylon lock nuts - Prevailing torque lock nuts - locking tabs (uncommon but OK)

Safety Wire - sometimes All fasteners in this picture are acceptable without positive locking mechanisms! (None are steering, suspension, harness, or brakes) (Chain scattershield missing…)

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