Giovanni Carrara!

Samples of Work!
 ASSEMBLY, TRILINK/DOGBONE PRESSING FIXTURE!
The Trilink and Dogbone are two structural components of the motorcycle's
rear suspension linkage system. Prior to being mounted onto the bike,
bearings and seals need to be pressed into the parts. These fixtures I
designed are mounted on an arbor press and used by the operators in a
subassembly station in our factory.!

8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION No REVISIONS

Arbor/QTY.
1 9902352-00 TRILINK PRESSING NEST 1 ZONE REV. DESCRIPTION DATE APPROVED
9
2 9902353-00 TRILINK PRESSING PIN 1
- - INITIAL DRAWING CREATED 04/29/16 G. CARRARA
D 7 D
D 3 9902354-00 TRILINK PRESSING PIN 2 1 7
D

4 9902355-00 TRILINK PRESSING PIN 3 1

5 90128A273 Socket Head Cap Screw M8x16 3

(McMaster) 16 11
6 90145A546 Dowel Pin 1/4 x 1 1/2 1

7 9902356-00 TRILINK PRESSING, BASE TOOL FIXATION 1 17

8 8507A110 Retractable Spring Plunger (McMaster) 1

9 91217A315 Set Screw M8x16 (McMaster) 2

10 90128A265 Socket Head Cap Screw M6x25 4

C (McMaster) 19 10 C C C

11 9902359-00 TRILINK PRESSING, TOOL ADAPTER 2

12 9902372-00 TRILINK PRESSING, BEARING DRIVER 1

HK2016
18
13 9902375-01 TRILINK PRESSING, BEARING SEAL BEARING 1 13
RBH
14 5600038-00 TRILINK 1 12 ITEM NO. PART NUMBER DESCRIPTION QTY.
2
15 4700298-01 BEARING, TRILINK, HK2016 1 3 1 9902315-00 REV 01 PIN, NO BEARING, DOGBONE 1
PRESSING FIXTURE
16 9902357-00 TRILINK PRESSING, BASE TOOL SLIDE IN 1 8 2 5600039-00 LINK, DOGBONE, REAR 2
8
1
B
17 9902358-00 TRILINK PRESSING, BASE TOOL SLIDE IN 2 1 B B
Press-Fit Locating Pin B
3 8472A25 Diamond, 0.5625" Diameter, 1-1/2" 2
18 9902589-00 TRILINK PRESSING, BEARING SEAL DRIVER, 1 Overall Length
SMALL 2 4 4
4 4700270-01 HK2220 Needle bearing 3
19 9902588-00 TRILINK PRESSING, BEARING DRIVER, SMALL 1
1 5 4700105-01 SEAL, 22x28-4KC-R2/MW 3
5
6 9902314-00 REV 01 NEST, DOGBONE PRESSING FIXTURE 1
6
5 7 9902317-00 REV 01 DRIVER, DOGBONE PRESSING 2
FIXTURE
6 3 8 9902316-00 REV 01 PIN, WITH BEARING, DOGBONE 1
PRESSING FIXTURE
FILE NAME: 9902351-00 FILE NAME:
THIRD ANGLE PROJECTION APPROVAL NAME DATE THIRD ANGLE PROJECTION APPROVAL NAME DATE
9902313-00 REV 01 ASSEMBLY, DOGBONE PRESSING FIXTURE
DRAWN G. CARRARA 5/13/2016 DRAWN F. LAST 10/7/2015
CHECKED
CAD GENERATED DRAWING,
DO NOT MANUALLY UPDATE ALTA MOTORS A CHECKED
CAD GENERATED DRAWING,
DO NOT MANUALLY UPDATE ALTA MOTORS A
A 185 Valley Drive, Brisbane, CA 94005 A 185 Valley Drive, Brisbane, CA 94005
ENG APPR. INTERPRET GEOMETRIC 415-230-0755 ENG APPR. INTERPRET GEOMETRIC 415-230-0755
TOLERANCING PER: TOLERANCING PER:
MFG APPR. ASME Y14.5-2009
UNLESS OTHERWISE SPECIFIED
ASSEMBLY, TRILINK MFG APPR. ASME Y14.5-2009
UNLESS OTHERWISE SPECIFIED
ASSEMBLY, DOGBONE
THE INFORMATION CONTAINED
IN THIS DRAWING IS THE SOLE
Q.A.
DIMENSIONS ARE IN MM.
TOLERANCES ARE:
PRESSING FIXTURE THE INFORMATION CONTAINED
IN THIS DRAWING IS THE SOLE
Q.A.
DIMENSIONS ARE IN MM.
TOLERANCES ARE:
PRESSING FIXTURE
COMMENTS: COMMENTS:
PROPERTY OF ALTA MOTORS. DECIMALS ANGLES PROPERTY OF ALTA MOTORS. DECIMALS ANGLES
ANY REPRODUCTION IN PART X 1.0 1 ANY REPRODUCTION IN PART X 1.0 1
OR WHOLE WITHOUT .X 0.1 REV. OR WHOLE WITHOUT .X 0.1 REV.
.XX 0.05 B PART NO.: 9902351-00 .XX 0.05 B PART NO.:
PERMISSION IS PROHIBITED. SIZE 01 PERMISSION IS PROHIBITED. SIZE 9902313-00 REV 01 ASSEMBLY,

DO NOT SCALE DRAWING SCALE: 1:5 g SHEET 1 OF 1 DO NOT SCALE DRAWING DOGBONE
SCALE: PRESSING FIXTURE
1:5 8009802.8g SHEET 1 OF 1
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
ALTA MOTORS SUPPLIER QUALITY HANDBOOK!
Many of the components on our motorcycle are done per our design by a
global supply chain. The purpose of this handbook that my team and I
developed and implemented is to ensure that the suppliers meet the
stringent requirements ALTA upholds. From Geometric Inspection Items,
to Appearance Standards, to Process Flows, every aspect of incoming
parts is controlled according to this document.!

SECTION A.2

SUPPLIER QUALITY ASSURANCE HANDBOOK

Table of Contents
Section
A.1 Revision History
A.2 Table of Contents

1.0 Introduction and General Information

2.0 Supplier Qualification
3.0 Designating Quality Contacts
4.0 Drawing Review for DFM
5.0 Significant Characteristics
6.0 First Article Submission and Approval
7.0 Component Inspection Standard

SUPPLIER QUALITY ASSURANCE HANDBOOK 8.0 Component Evaluation Plan

9.0 Process Flow Diagram
10.0 Process Failure Modes and Effects Analysis
11.0 Control Plan
12.0 Appearance Standards / Boundary Sample
13.0 Part Approval
14.0 Process Change Request
15.0 Nonconforming Materials

www.altamotors.co 185 Valley Dr, Brisbane, CA 94005 DOC# 9701730-00 Alta Motors SQAH Rev. 1 PROPRIETARY & CONFIDENTIAL 2
ASSEMBLY, OFFBOARD CHARGER TESTER!
ALTAs offroad MX version of the motorcycle comes with an offboard
charger, assembled by a supplier. Prior to shipping, 100% of the
chargers are tested using this test fixture I designed, sourced and
assembled. There is an 8020 extrusion frame, a Battery and an
enclosure containing all the electrical components to simulate a bike.
The tool can also be used to charge batteries offboard bikes.!
8 7 6 5 4 3 2 1

REVISIONS
2
ZONE REV. DESCRIPTION DATE DRAWN

01 INITIAL DRAWING CREATED 5/16/2017 G. CARRARA

1
D D

C C

B B

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 9903662-00 OFFBOARD CHARGER TESTER, 1
FRAME
2 8800007-00 BATTERY, 6x84 1

3 9903568-00 OFFBOARD CHARGER TESTER, 1

ENCLOSURE, 75065K720
FILE NAME: 9903372-00
THIRD ANGLE PROJECTION APPROVAL NAME DATE

DRAWN G. CARRARA 5/16/2017

CHECKED
CAD GENERATED DRAWING,
DO NOT MANUALLY UPDATE ALTA MOTORS A
A 185 Valley Drive, Brisbane, CA 94005
ENG APPR. INTERPRET GEOMETRIC
415-230-0755
TOLERANCING PER:
MFG APPR. ASME Y14.5-2009

UNLESS OTHERWISE SPECIFIED

ASSEMBLY, OFFBOARD
THE INFORMATION CONTAINED
IN THIS DRAWING IS THE SOLE
Q.A.
DIMENSIONS ARE IN MM.
TOLERANCES ARE:
CHARGER TESTER,
PROPERTY OF ALTA MOTORS.
ANY REPRODUCTION IN PART
COMMENTS: DECIMALS
X 1.0
ANGLES
1
LEEMAH
OR WHOLE WITHOUT .X 0.1 REV.
.XX 0.05 B PART NO.: 9903372-00
PERMISSION IS PROHIBITED. SIZE

DO NOT SCALE DRAWING SCALE: 1:10 21596631.8g SHEET 1 OF 2

8 7 6 5 4 3 2 1
ASSEMBLY CART, MAIN LINE!
The assembly cart is designed to provide a set of wheels before the
motorcycle can roll by itself. My role was to consolidate various
concepts that had been ideated into one working and easy to
manufacture assembly. There are currently 8 carts being rotated
through the assembly line.!
8 7 6 5 4 3 2 1

REVISIONS
ZONE REV. DESCRIPTION DATE DRAWN

01 INITIAL DRAWING CREATED 10/06/16 G. CARRARA

D D

C C

2 4

1
B ITEM NO. PART NUMBER DESCRIPTION FLOATING/QTY. B

1 9902545-00 ASSEMBLY, BASE, CART, MAIN LINE 1

2 9902510-00 ASSEMBLY, MODIFIED, LIFT, SCISSOR, 1

K&L
3 9902552-00 ASSEMBLY, RBH INTERFACE, CART, 1
MAIN LINE
4 91502A232 SCREW, SOCKET HEAD, M10X65 4
5 BATTERY CART LEAD IN 1
6 CORE STRUCTURE 1
FILE NAME: 9902502-00
THIRD ANGLE PROJECTION APPROVAL NAME DATE

5 DRAWN F. LAST 10/7/2015

CHECKED
CAD GENERATED DRAWING,
DO NOT MANUALLY UPDATE ALTA MOTORS A
A 185 Valley Drive, Brisbane, CA 94005
ENG APPR. INTERPRET GEOMETRIC
415-230-0755
TOLERANCING PER:
MFG APPR. ASME Y14.5-2009

UNLESS OTHERWISE SPECIFIED

ASSEMBLY, CART, MAIN
THE INFORMATION CONTAINED
IN THIS DRAWING IS THE SOLE
Q.A.
DIMENSIONS ARE IN MM.
TOLERANCES ARE:
LINE
COMMENTS:
PROPERTY OF ALTA MOTORS. DECIMALS ANGLES
ANY REPRODUCTION IN PART X 1.0 1
OR WHOLE WITHOUT .X 0.1 REV.
.XX 0.05 B PART NO.: 9902502-00
PERMISSION IS PROHIBITED. SIZE 01
DO NOT SCALE DRAWING SCALE: 1:20 799221.5g SHEET 1 OF 1
8 7 6 5 4 3 2 1
ASSEMBLY, TOOL, MOUNTING, MOTOR!
This tool I designed serves the needs of the Assembly Line, Dealers,
R&D, and Engineering. The purpose is to provide a lever arm for the
O-Ring seals to be pressed into the main Aluminum component of the
frame. The part is manufactured from billet 6061-T6 Aluminum with a
handle and a grip.!
8 7 6 5 4 3 2 1

REVISIONS
ZONE REV. DESCRIPTION DATE DRAWN

01 INITIAL DRAWING CREATED 5/15/2017 G. CARRARA

D D

C C

5 1
2 4

B B
ITEM NO. PART NUMBER DESCRIPTION QTY.

1 7702473-01 TOOL, MOUNTING, MOTOR, 1

WRENCH HEAD
2 7703548-01 TOOL, MOUNTING, MOTOR, HANDLE 1

3 91294A240 BLACK ALLOY STEEL FLAT-HEAD 2

SOCKET CAP SCREW
4 3203496-00 GRIP, SET, RENTHAL, MEDIUM, FULL 1
DIAMOND, DARK GREY
5 7703650-00 ASSEMBLY, STUD, TOOL, MOUNTING, 2
MOTOR
FILE NAME: 7703518-01
THIRD ANGLE PROJECTION APPROVAL NAME DATE

DRAWN G. CARRARA 5/15/2017

CHECKED
CAD GENERATED DRAWING,
DO NOT MANUALLY UPDATE ALTA MOTORS A
A 185 Valley Drive, Brisbane, CA 94005
ENG APPR. INTERPRET GEOMETRIC
415-230-0755
TOLERANCING PER:
MFG APPR. ASME Y14.5-2009

UNLESS OTHERWISE SPECIFIED

ASSEMBLY, TOOL,
THE INFORMATION CONTAINED
IN THIS DRAWING IS THE SOLE
Q.A.
DIMENSIONS ARE IN MM.
TOLERANCES ARE:
MOUNTING, MOTOR
COMMENTS:
PROPERTY OF ALTA MOTORS. DECIMALS ANGLES
ANY REPRODUCTION IN PART X 1.0 1
OR WHOLE WITHOUT .X 0.1 REV.
.XX 0.05 B PART NO.: 7703518-01
PERMISSION IS PROHIBITED. SIZE

DO NOT SCALE DRAWING SCALE: 1:5 556.3g SHEET 1 OF 1

8 7 6 5 4 3 2 1
ASSEMBLY, TOOL, SPRING PIN, M4, RBH!
This tool I designed and assembled is used on the Main Assembly
line by the operators to insert Locating Spring pins into the bike. A pin
and a magnet hold the pin in place while the operators use a small
hammer to drive it in.!

8 7 6 5 4 3 2 1

REVISIONS
ZONE REV. DESCRIPTION DATE DRAWN

01 INITIAL DRAWING CREATED 11/30/2016 G. CARRARA

1INCH HEAT SHRINK
D D

C C

B B
1
ITEM NO. PART NUMBER DESCRIPTION QTY.
3 1 8486A422 Press-Fit Drill Bushing 4mm ID, 8 mm 1
Long
2 9903029-00 TOOL, SPRING PIN INSERT, M4, RBH 1
3 91595A175 Metric Alloy Steel Dowel Pin M4 1
Diameter, 26 mm Length

4 9903037-00 TOOL, MAGNET, SPRING PIN INSERT, 1

M4, RBH
FILE NAME: 9903030-00
THIRD ANGLE PROJECTION APPROVAL NAME DATE

DRAWN G. CARRARA 11/30/2016

CHECKED
CAD GENERATED DRAWING,
DO NOT MANUALLY UPDATE ALTA MOTORS A
A 185 Valley Drive, Brisbane, CA 94005
ENG APPR. INTERPRET GEOMETRIC
415-230-0755
TOLERANCING PER:
4 MFG APPR. ASME Y14.5-2009
ASSEMBLY, TOOL,
UNLESS OTHERWISE SPECIFIED
THE INFORMATION CONTAINED
IN THIS DRAWING IS THE SOLE
Q.A.
DIMENSIONS ARE IN MM.
TOLERANCES ARE:
SPRING PIN INSERT,
PROPERTY OF ALTA MOTORS.
ANY REPRODUCTION IN PART
COMMENTS: DECIMALS
X 1.0
ANGLES
1
M4, RBH
OR WHOLE WITHOUT .X 0.1 REV.
.XX 0.05 B PART NO.: 9903030-00
PERMISSION IS PROHIBITED. SIZE

DO NOT SCALE DRAWING SCALE: 1:1 11180.8g SHEET 1 OF 1

8 7 6 5 4 3 2 1