This week, a film crew on assignment for London’s Channel 4 stopped by our Springfield, Missouri workshop. As part of their series “World’s Most Extreme” that focuses on vehicles designed for extreme usage conditions, they wanted to record our Tornado Puncher as it underwent a gauntlet of tests. As the engineer responsible for assessing the validity and significance of these tests, I was on set with my laptop as we simulated tornado wind loading and debris impacts. They mic’ed me up to capture my genuine reactions as a monster truck drove over the Puncher and more, interviewing me on camera about the engineering considerations of the vehicle and the test’s implications afterwards. In as natural and unscripted a way as possible, I’ll take you through the action of the day from my angle.
First, let me introduce the vehicle: a brainchild of my friend Russel Gehrke, the Tornado Puncher is a one-person vehicle designed to drive into the path of a tornado and lower to the ground. It combines automobile aerodynamics with 5 years of tornado shelter engineering, merging wind resistance with debris impact durability. The body is 1/4″ steel coated with a polyurethane exterior for impact energy absorption. The V8 engine and chassis are from a low-mileage 1977 Chevrolet Blazer, the frame shortened by 3 feet and engine moved to fit inside the compact angularity of the body. I’ve been working with him on this monster of a vehicle on and off since Fall 2016, both as a second set of hands and as a sounding board for design considerations. Here is a picture of the Puncher as we ran over it with a 5000-lb rock crawler (showing that the Puncher’s chassis could withstand an additional 2000+ pounds of loading, e.g. a tree falling on the vehicle during a storm):
For the most exciting test, we rented a 30-ton load cell to see how much force it would take to push or tip the Puncher from the side. Because the aerodynamic drag from perpendicular winds is greater than winds from the front or rear, this test was designed to determine the wind loading threshold that the vehicle could withstand in the field. We hooked the rock crawler to the load cell, which was attached to two tow hooks spanning the aerodynamic centroid on the left side of the Puncher. The rock crawler dug its tires into the dirt and gradually ramped up its thrust in an attempt to tow the Puncher sideways across the field. The load cell maxed out at 6200 pounds before the rock crawler’s tires lost traction with the ground and started spinning. Based on the dimensions of the Puncher and the knowledge that windspeed increases with height, 6200 pounds of force represents the load of a sustained wind at 145 mph, corresponding to an EF3 tornado. The position of the vehicle did not budge, indicating that the threshold for tipping or sliding is actually significantly higher than the recorded 6200 lb. However, the test gives us confidence that the Puncher can withstand an EF3 tornado when lowered to the ground in ‘deployment mode.’
As a finale, we demonstrated impact resistance by using an air cannon to fire representative debris at the side of the Puncher. First, dowel rods at 2-foot and 4-foot lengths were shot at around 100 mph. The wood splintered as it pinged off the side of the vehicle, slightly nicking the polymer coating while leaving the steel intact. Then, we fired a scattershot of spherical ice cubes, varying in size from about 1-1 1/2 inches to represent hail. The ice shattered harmlessly into smithereens upon impact, making for a mesmerizing slo-mo shot. All in all, it was a cool way to spend the past couple of days, at a great location in the Southern Missouri Off-Road Ranch near Seymour. I’ll keep you posted about the show: if I’m not on TV in a few months, at least I’ll be all over the cutting room floor back in London!