Toro Rosso have released a youtube video of a complete factory tour. Both informative and in depth, the video shows us some detail of the car we do not usually get to see.
From the CAD screens we can see the general arrangement of the nose cone, the parts listed on the top right include each of the small covers that close up the apertures for sensors etc on the nose cone.
This side elevation of the nose cone shows us its exact dimensions. Obviously a 2012 nose cone due to the lack of a vanity panel.
These are the part of the quarter turn fastening system that hold the nose onto the chassis.
This appears to be a FEA analysis of the nose front wing assembly, with the yellow and red sections being at the highest stress.
In CAD we can see the entire (albeit with some parts removed) rear suspension. There are upper and lower wishbones (red) holding the upright (orange). The rotating inner parts of the driveshaft, CV joints, stub axle and wheelnut are all fully detailed.
The brake caliper is missing and mounts the lift of the upright, note the upper mounting for the caliper and top rear wishbone is extremely slim. Uprights have to be made from Aluminium, with the loads of the wishbone, brake and pull rod this is area is very highly stressed.
The pull rod (black) operates the two rockers, (light blue & dark blue). Inside the rockers are the torsion bars to provide the spring effect. As the rockers rotate they compress the dampers (only one shown – grey) and at their tops a pair of levers compress the heave element (not shown). No levers are shown for the anti roll bar or inerter, although these are almost certainly set up options for the rear suspension.
Wishbones are made from Carbon fibre and wilL be rig tested after each use to ensure they are not cracked.
In side elevation this hand drawing shows the moncoque in cross section. You can see how much volume under the fuel tank that KERS takes up. It’s unusual for teams to use drawing boards (Newey excepted) aside from the early layout of a new car.
The crash test gives us a uniquely clear view of the bare monocoque. First note the roll hoop, the recent STR’s have all had extremely undercut roll hoops the upper inlet being supported by slim pylons. Here we can see the metal inner section forming the structure itself. Typically these are machined or 3D-printed from aluminium or titanium. Below this area we see where the radiators are mounted to the flanks of the tub. This area is recessed and above and below the tub bulges outwards to create more space for the fuel tank, thus keeping the monocoque shorter for better aero.
This first CFD image is quite hard to visualise at first. its a view through the car somewhere just above flow level, the front wheels are to the left and the white central section is the monocoque\engine. You can even make out the exhaust pipes as white circles to the right.
The image shows flow velocity, with red being faster airflow. Starting at the left, you can see two strong red traces running towards the right. These are the Y250 vortices running off the front wing, note how they separate the messy flow around the front wheels from the chassis and how they are aimed at the white pod vanes either side of the chassis. The other red area on the left is the flow passing between the undernose turning vanes.
To the right you can see the exhaust plumes exiting near the coke bottle shape (this is probably a pre 2012 car).
These are streamlines passing over the top of the chassis and under the beam wing. Note how much the upwash effect is. This is the turbulent airflow the following car runs into when trailing another car.
Lastly this image is a vertical cross section through the rear suspension of the car. You can make out the floor of the car and stepped bottom in white. Above this is the gearbox, the hot air exit and the inverted “V” of the top body. Either side the teardrop shapes are the wishbones and pull rods cross sections. Swirls of red\green to the sides are the flow being whipped up by the rear brake ducts
This is a late 2013 wind tunnel model (note the tunnel sidepods). the model in built around a central aluminium spine with contains the electronics and sensors. Then the external air-licked panels are fitted, these are made from carbon fibre, aluminium or 3D prototype resins. Panel gaps are covered with aluminium tape to seal the edges. You can tell which bodywork areas are important, by the split lines that exist on the model and not on the real car. This allows the model to be more flexible and allows the aerodynamicists to investigate specific areas without having to make complete bodywork sections, just the sub sections.