Case Study: Custom Exoskeleton Build for DTi Creative’s Marching Band Vehicles

Challenge: Addressing Logistical Issues with Temporary Vehicle Modifications

Dot The i Creative (DTi) specializes in building custom props and banners for collegiate marching bands. Each year, they are tasked with creating a unique vehicle to enhance the band's performance. Historically, they modified rented golf carts for this purpose, but this approach presented multiple logistical challenges, including vehicle availability, safety concerns, and design limitations.

To overcome these issues, DTi sought to modify a 4x2 John Deere Gator with a durable and adaptable exoskeleton that would allow for future vehicle transformations while maintaining the safety and functionality of the base vehicle. Upcoming projects required the ability to convert the Gator into both a Lunar Rover and a Pirate Ship, demanding a solution that was both structurally sound and versatile.

‍Solution: A Custom-Built Exoskeleton by Wolf Metals

Wolf Metals engineered a modular aluminum exoskeleton designed to attach securely to the undercarriage of the Gator without compromising its integrity. The structure allows DTi to build different vehicle concepts onto the frame without making permanent modifications to the vehicle itself.

Engineering Highlights:

• Material: Constructed from 2-inch rectangular aluminum tubing for strength and lightweight properties.
• Attachment System: 1/4-inch holes drilled every 2 inches along the tubing, enabling easy mounting of external vehicle structures.
• Structural Capacity: Engineered to support up to 1,200 lbs to accommodate large-scale performance builds.
• Modular Design: The exoskeleton consists of two welded sections, allowing for straightforward assembly and disassembly as needed.

Precision Fabrication Process

Wolf Metals leveraged its advanced fabrication technology to ensure the exoskeleton met high-performance and durability standards.

Equipment Utilized:

• Tube Laser: Enabled precise cutting of aluminum tubing for uniform hole placement and seamless assembly.
• Flat Laser: Provided accurate shaping of metal plates used in securing the frame to the vehicle.
• Bend Cell: Allowed for precise bending of components to ensure a custom fit to the Gator’s chassis.

How It Works: Assembly & Customization

The new exoskeleton system allows DTi to easily attach and swap out themed vehicle builds with minimal downtime.

Step 1: Frame Installation

The aluminum exoskeleton is securely bolted to the Gator’s undercarriage, ensuring stability while allowing for easy removal when necessary.

Step 2: Concept Buildout

DTi designers construct themed vehicles—such as a Pirate Ship or Lunar Rover—using lightweight materials that can be attached to the exoskeleton via pre-drilled mounting points.

Step 3: Performance Adjustments

Structural reinforcements, platforms, and performance features (such as steering visuals and performer placement) are added to enhance realism.

Step 4: Safety & Testing

The entire setup undergoes testing to ensure balance, mobility, and driver visibility. In the case of the Pirate Ship, a front-mounted camera with a dashboard monitor was installed to assist with navigation and eliminate blind spots.