Taking Shape

February 21th, 2019

The rented storage space wasn't glamorous, but it was practical. Located in a warehouse complex a few kilometers from the university, it offered ample room to store the materials they had spent the past two weeks gathering. Matthew stood in the middle of the space, glancing around at the organized chaos: stacks of aluminum sheets, steel tubing, crates of lithium-ion cells, and boxes containing seats, dashboards, and premium interior components Samantha had sourced.

The space smelled faintly of metal and fresh paint, the echoes of their footsteps bouncing off the high ceilings. A workbench stood in one corner, complete with tools Saimon had borrowed from his dad's shop, while another corner was reserved for the whiteboard and their meeting setup.

Matthew wiped his hands on his jeans and addressed the group, who were seated on folding chairs arranged in a semicircle.

"Well," he began, gesturing at the neatly arranged materials, "after three weeks of late nights, negotiations, and more Grab rides than I can count, we finally have everything we need."

Saimon stretched his legs out and grinned. "And no major mishaps. I'd call that a win."

"Speak for yourself," Leo muttered, rubbing his shoulder. "I'm still sore from hauling that steel tubing."

"Worth it," Samantha said coolly, her gaze sweeping over the collection. "Now comes the real challenge—turning this into a functioning EV."

Matthew nodded, his expression serious. "Exactly. So, the question is: where do we start? I've got a flowchart to answer that."

He picked up a marker and turned to the whiteboard, where a detailed flowchart was already drawn. The group leaned forward as he began to explain.

"We'll start with the chassis and frame. That means welding the aluminum sheets and steel tubing into the structure of the car. This step is critical because it forms the foundation for everything else. Saimon, since your dad's shop has welding equipment, you'll take the lead on this."

Saimon gave a mock salute. "Got it, boss."

"Once the frame is complete, we'll move on to the powertrain. This includes mounting the electric motor and attaching the controller. We'll wire them up and run a basic test to ensure they communicate properly."

Leo raised his hand. "What if they don't communicate? You've got a backup plan, right?"

Matthew smirked. "Of course. We've got diagnostic software and a spare controller, just in case."

"Next, we'll integrate the battery pack. We'll assemble the cells into modules, install the battery management system, and mount the pack onto the chassis. Safety is non-negotiable here, so we'll double-check everything."

Samantha interjected. "I've already spoken to a supplier about additional safety brackets and insulation. I'll make sure they're delivered before this phase."

Matthew nodded appreciatively. "Perfect."

"After the battery is secured, we'll install the suspension and steering components. These are parts that we bought from Toyota, used in Wigo." 

Leo grinned. "So, basically, we're giving our EV a Wigo's bones. Not bad."

Saimon chuckled. "Hey, if it works, it works. Plus, it's sturdy enough for city driving, and we're not reinventing the wheel here."

Matthew nodded, his expression focused. "Exactly. The suspension is critical to the car's performance. It needs to handle the added weight of the battery pack while keeping the ride smooth. That's why we've tested and refurbished these parts. Once this is done, we'll move to the interior installation."

He turned his attention to Samantha. "You're in charge of overseeing the installation of the seats, dashboard, and any premium interior components you sourced. Presentation is key for this phase—it's the first thing anyone will notice about the car."

Samantha tilted her head, her tone calm but firm. "I've got it under control. Everything I ordered is designed to fit our chassis, and I've already lined up a vendor for custom upholstery."

"Good," Matthew replied, jotting her name beside the task on the whiteboard. "After that comes system integration and testing. This is where we'll bring everything together—powertrain, electronics, and interior features. It's the final stage before we run our first full system test."

Leo leaned back in his chair, crossing his arms. "Sounds like a plan, but how are we splitting the workload? We've got a lot to do, and not a ton of time."

Matthew smirked and tapped the flowchart. "I've already divided the tasks. Saimon and I will handle the frame and mechanical installations. Leo, you'll assist with the suspension and testing. Samantha, you'll be on interior and finishing touches."

Leo gave an exaggerated sigh. "No escape, huh?"

"Nope," Matthew replied, his grin widening. "Everyone pulls their weight."

The group stood around the workbench, with Saimon holding up a blueprint of the chassis. "Alright," Saimon said, slapping the blueprint onto the table. "Let's get started. I'll begin welding the frame."

Matthew adjusted his gloves and safety goggles. "I'll assist. We need to make sure the dimensions are perfect. The motor and battery won't fit if the frame's off by even a millimeter."

Samantha and Leo watched as the two got to work, sparks flying as Saimon expertly welded the aluminum and steel components. Matthew measured each joint meticulously, ensuring the pieces lined up with the blueprint.

Samantha leaned closer to Leo, her arms crossed. "This is going to take hours."

Leo shrugged. "Better it takes hours than it's done wrong. Let's just hope Saimon's hands don't cramp."

By March 7th, the chassis was complete. The team stood around the gleaming frame.

"Not bad for a couple of students," Saimon said, wiping sweat from his forehead.

Matthew patted him on the back. "You did great. Now we move on to the powertrain."

The group worked like a well-oiled machine, mounting the electric motor onto the frame and wiring it to the controller. Despite a few hiccups—like a misaligned bracket that took an hour to fix—they made steady progress.

By the end of the week, the battery pack was ready to be integrated. Samantha had ensured the safety brackets and insulation arrived on time, and Saimon's dad's tools proved invaluable in testing each module.

Samantha watched as Matthew connected the battery management system. "How soon before we can run the first power test?"

Matthew glanced up from his work, a small smile on his face. "If everything goes smoothly, we can power it up next week."

Leo let out a mock groan. "More waiting? I was hoping to see it drive by tomorrow."

"Patience," Matthew said, chuckling. "You'll get your test drive soon enough. For now, let's focus on finishing each step properly."

By March 14th, the team reconvened at the storage space. The powertrain installation was complete, and the chassis gleamed under the overhead lights. With the technical core of the EV in place, it was time to bring the car to life visually—starting with the interior.

Matthew gathered the group around the frame, flipping his clipboard to reveal the next phase of the flowchart.

"Alright, team. Next up: the interior. This is where we turn our prototype into something that doesn't just function but feels polished and professional," he said, pointing to a detailed sketch of the cabin layout.

Samantha stepped forward, her arms crossed. "I've already confirmed the measurements of the seats, dashboard, and trim components with the chassis. Everything should fit seamlessly."

"Good," Matthew said with a nod. "You'll oversee the installation while Leo and I focus on mounting the infotainment system. Saimon, you're on wiring duty. We need the interior electronics connected and tested before the dashboard is fully secured."

Saimon grinned, twirling a set of pliers. "Wiring? Easy. Just don't expect me to upholster anything."

Leo laughed. "Don't worry, I'm leaving that to Samantha and Matthew. I don't trust myself with fabric or stitching."

The team got to work. Samantha meticulously directed the placement of the plush, ergonomic seats she had sourced, ensuring each one was bolted in with precision. The custom dashboard—a sleek design with soft-touch materials—was carefully aligned and mounted by Matthew and Leo. They worked as a team to connect the dashboard's wiring harness to the central system, their movements synchronized like seasoned pros.

The storage space buzzed with activity, the hum of power tools blending with the occasional bursts of laughter and chatter. Saimon crouched near the driver's side door, deftly routing wires for the steering controls and touchscreen display.

"This infotainment system is going to blow people's minds," Leo remarked, holding up the glossy display screen. "Are we sure this isn't overkill?"

Samantha, standing nearby and adjusting the armrest console, gave him a sharp look. "There's no such thing as overkill in presentation. It's the first thing people see when they step inside. It has to make an impression."

By the end of the day, the interior started taking shape. The sleek black dashboard, complemented by ambient lighting strips Samantha had insisted on, gave the cabin a futuristic vibe. The seats, upholstered in premium fabric with subtle stitching, looked and felt luxurious. The centerpiece, however, was the infotainment system—a large touchscreen mounted seamlessly in the middle of the dash, flanked by modern air vents and a compact control panel.

"Damn," Saimon muttered, standing back to admire their work. "This looks… expensive."

"That's the point," Samantha said simply, brushing a speck of dust off the console. "It needs to look like something people would want to buy, not just a student project."

Matthew stepped into the driver's seat, running his hands over the steering wheel and dashboard. He tapped the touchscreen, which lit up with a responsive interface.

"Not bad," he said with a grin. "It's functional, sleek, and modern. Great work, everyone."

Leo leaned against the car door, wiping sweat from his forehead. "So… when do we take this baby for a spin?"

"When it has aircons, headlights, tail lights, wipers…It will take about a month." 

"A month?!" 

"Yup," Matthew replied. "So let's lock in for a month now and we will be able to take our vehicle into spin."