Added sections for cost event, gave basic definitions and official feedback from FTX7. Updated cost and design judging notes based on notes recorded by Harry, Donal and Ellena

docs/competition/scrut/chassis/index.md

@@ -5,17 +5,29 @@ For chassis scrutineering, ensure you have printed copies of the **Structural Eq
 Chassis scrutineering checks that the manufactured chassis matches the approved SES. Scrutineers also:
 
 - Inspect weld quality
-- Check the wall thickness of steel tubes
+- Check the wall thickness of steel tubes using an ultrasonic probe
 - Weigh the car
 - Check the roll envelope
 - Fit a Percy model and confirm the required clearance from the roll envelope
 - Check the cockpit opening and internal cross-section using the relevant templates
 
+For the tube wall-thickness check, scrutineers apply a coupling paste to the tube and place an ultrasonic probe against it. Make sure the tubes being checked are clean and accessible.
+
+Be ready to remove the seat so the scrutineers can inspect the firewall and fit the cockpit-opening template. The seat must be installed for the internal cross-section check from the driver's legs to the pedal box (*supposedly, but this was not enforced for* **FTX7**). Check that the firewall is fully sealed around its edges and that any tape used is secure, particularly beside the driver's head.
+
+The Percy check uses a physical 3D driver template based on the 2D dimensions in the rules. Rehearse the check with the seat, pedal box and firewall set up. Do not **rely** on being allowed to position Percy directly against the firewall or to pass its feet through openings around the pedal box (*this was allowed for FTX7, but wouldn't bank on it every time*). Building an accurate Percy template for workshop checks can help identify clearance problems before competition.
+
+Scrutineers check the driver's helmet clearance from the roll envelope by placing a straight edge across the two roll hoops. The required clearance may only be measured if it looks close, so rehearse the check and make the clearance clearly visible before competition. Use the same method to check that the powertrain intake remains within the permitted roll envelope.
+
+The car is weighed on a large platform scale. Bring the car and every item that must be included in its configuration so that the complete assembly can be weighed together.
+
 ## Checklist
 
 - Bring printed copies of the SES and Impact Attenuator Data Sheet.
 - Bring the physical sample used for the impact attenuator test.
 - Check that the manufactured chassis matches the approved SES.
 - Inspect weld quality before presenting the car.
-- Be ready for tube wall thickness checks.
-- Check roll envelope, Percy clearance, cockpit opening and cockpit internal cross-section before queueing.
+- Clean the chassis tubes and make them accessible for ultrasonic wall-thickness checks.
+- Make sure the seat can be removed easily for the firewall and cockpit-opening checks.
+- Rehearse the Percy, helmet-clearance, intake roll-envelope, cockpit-opening and internal cross-section checks using the intended seat, pedal box and firewall configuration.
+- Bring every item required for the car's measured configuration to the weigh-in.

docs/competition/scrut/index.md

@@ -25,8 +25,11 @@ The completeness of the pre-scrutineering form determines the team's position in
 - Check [FS Stats](https://www.fsstats.co.uk/) for live information on non-conformities during scrutineering.
 - Bring the most relevant four people for the stage being attempted.
 - Keep the printed rules available with any rules likely to be questioned highlighted.
-- Bring the required supporting documents and physical test samples for the stage.
+- Bring the required supporting documents and physical test samples for the stage. Tab important pages so they can be found quickly.
+- Organise specification sheets and certificates for safety-critical materials and bought parts before the event.
 - Inspect the car in the pits before each attempt, especially after any repair or adjustment.
 - Record issues raised by scrutineers (even warnings).
 
+---
+
 ![scrut sticker](../../assets/images/competition/scrut/scrut_sticker.jpg)

docs/competition/scrut/safety/index.md

@@ -4,13 +4,25 @@
 
 Safety Scrutineering assesses whether the car can be operated safely. This includes both specific rule requirements and also more general hazards identified during inspection.
 
-Scrutineers might raise concerns even when there is no rule directly describing the issue, particularly where workmanship, component security, sharp edges, routing or access could create a safety risk. Some judgement and common-sense is therefore involved, and concerns can vary between scrutineers.
+Scrutineers might raise concerns even when there is no rule directly describing the issue. Following the wording of the rules is not enough if workmanship, component security, sharp edges, routing or access still creates a safety risk. Some judgement and common-sense is therefore involved, and concerns can vary between scrutineers.
+
+Expect mounted parts to be pushed or shaken during inspection. The floor, bodywork, intake, fuel rail and other assemblies should remain secure without excessive movement, gaps or rattling. Seal bodywork gaps where appropriate and remove or cover any sharp edges.
+
+Scrutineers inspect critical fasteners closely and may ask which locking method has been used. Check that each critical fastener has the required thread engagement, washers and positive locking method. This includes fasteners on items such as the chain guard and suspension springs. Do not use nylon-insert lock nuts where heat from the engine or brakes could affect them, use a suitable heat-resistant locking method (k-nuts).
+
+Bring the complete set of driver equipment for inspection. At FSUK 2026, drivers did not need to wear the full suit while it was being checked. Hand restraints should be looped through the harness before it is fastened. Check the current harness requirements carefully if the seat is reclined, particularly the anti-submarine belt arrangement.
 
 ## Checklist
 
 - Check that loose items, wiring, hoses and other components are securely retained.
-- Check for sharp edges or exposed features that could injure a driver, marshal or team member.
-- Check that fluid lines, cables and moving parts are routed safely.
+- Check that the floor, bodywork, intake and fuel rail are securely supported.
+- Check bodywork for gaps, movement, rattling and sharp edges.
+- Trim cable ties flush and cover exposed fasteners in the cockpit, especially around the driver's legs.
+- Fit rule-compliant head-restraint padding anywhere the driver's helmet could contact the roll structure, insulation foam is **not** suitable.
+- Cover the steering column and steering rack wherever the driver could contact them, insulation foam can be used (*pool noodle*).
+- Check that brake lines are routed fully clear of the wheels through the complete range of steering and suspension movement.
+- Use fuel-rated hose clamps rather than general-purpose worm-drive clips in the fuel system.
+- Check all critical fasteners for security, thread engagement, washers and the required locking method.
 - Check that safety-critical items can be inspected clearly.
 - Prepare to explain any design choices that depend on judgement rather than a single explicit rule.
 - Record any concerns raised, even if they are not tied to a specific rule number.

docs/competition/scrut/tech/index.md

@@ -6,12 +6,17 @@ Technical Scrutineering largely consists of checks against the rules. You should
 
 Highlight any rules you expect questions about and be prepared to explain how the car complies. Where a rule is open to interpretation, clearly justify your interpretation and why the design still satisfies its intent. Do not be afraid to argue your case respectfully.
 
+Do not expect every check to involve a measuring tool. Scrutineers may move the suspension, shake mounted components or ask a driver to press a pedal firmly. Measure and test these items in the workshop rather than relying on them looking acceptable at competition.
+
 ## Checklist
 
 - Bring a printed copy of the rules.
 - Highlight rules that are likely to be questioned.
+- Bring the relevant material certificates and specification sheets, including those for head-restraint padding, seat fabric and other safety-critical bought parts.
 - Prepare short explanations for any rules requiring interpretation.
 - Make sure relevant team members understand how the car complies.
+- Test suspension travel and the pedal box against the current rule requirements before competition.
+- Check that the steering has positive stops and that cable-operated pedals reach a positive stop before loading the cable.
 - Record any issues raised and the rule numbers they relate to.
 
 ---

docs/competition/statics/cost/index.md

@@ -1,3 +1,31 @@
-# Cost & Manufacturing
+# Cost & Manufacturing Event
 
-*Work in progress...*
+Cost & Manufacturing Judging assesses how well the team understands the cost, manufacturing and carbon footprint of the car.
+
+The team submits its costing and carbon documentation before the competition, then attends a judging session where judges examine selected parts of the car and question the team on the assumptions and methods used:
+
+- [Cost Report Documents](./pre_comp_submissions/index.md)
+- [In-Person Judging](./judging/index.md)
+
+---
+
+## How it Works
+
+- A particular area of the car is selected before the competition for more detailed Cost & Manufacturing judging.
+- The team prepares this area particularly well and ensures it is fully costed and carbonised.
+- The two specific components the judges want to inspect are only revealed during the judging session.
+- For **FTX7**, the selected area was **Engine & Tractive System**, corresponding to our [**Powertrain**](../../../ftx7/powertrain/index.md) department.
+- The components selected during judging were the **Plenum & Restrictor** and **Fuel Tank**.
+
+Up to **10 team members** can attend the judging session. Ideally, attendees should collectively be familiar with the selected department, the CCBOM, cost assumptions, carbon calculations and team-level financial decisions.
+
+---
+
+## What is Assessed?
+
+The Cost & Manufacturing event is judged under four categories:
+
+- Content & completeness of the BOM
+- Realism of cost estimation
+- Realism of carbon footprint estimation
+- Cost understanding

docs/competition/statics/cost/judging/index.md

@@ -0,0 +1,147 @@
+# Cost & Manufacturing Judging
+
+The Cost & Manufacturing judging session assesses the team's understanding of the [submitted documentation](../pre_comp_submissions/index.md) and its ability to justify the cost, carbon and manufacturing decisions made.
+
+Up to **10 team members** can attend the session. The exact format and number of judges may vary between years.
+
+---
+
+## What to Bring
+
+- A printed copy of the CCBOM for reference during discussion.
+- A searchable copy (*using* `ctrl+F`) of the CCBOM on a laptop so selected components can be found quickly.
+- Two full printed sets of drawings so multiple judges can inspect them at the same time.
+- Assembly drawings and fully dimensioned manufacturing drawings for the selected area.
+
+The drawings and CCBOM should work as a complete manufacturing package: together, they should contain enough info for someone outside the team to make and assemble the relevant components.
+
+---
+
+## Judging Format
+
+### Introductory Questions
+
+Judging began with some general questions about how cost is managed within the team. For FTX7, this included questions such as:
+
+- What is the team's overall budget?
+- Are individual department budgets set?
+- Who is responsible for cost within the team?
+- Does the team have a dedicated Cost Lead?
+
+FTX7 did not have individual department budgets or a designated Cost Lead.
+
+Before judging, prepare the overall budget, actual expenditure and a clear explanation of how spending is approved and monitored. If the team does not allocate departmental budgets (*we didn't for FTX7*), be ready to explain the alternative process and identify who has responsibility for final spending decisions.
+
+### Selected Components
+
+Before competition, the team is informed of the area of the car which will receive detailed Cost & Manufacturing assessment. However, the specific components examined are only revealed during the judging session.
+
+For FTX7, the selected area was **Engine & Tractive System**. During judging, the judges selected:
+
+- **Plenum & Restrictor**
+- **Fuel Tank**
+
+The team was then asked to locate these components within the [**CCBOM**](../pre_comp_submissions/CCBOM.md) and walk through their contents.
+
+### CCBOM Walkthrough
+
+The judges examined the selected components in detail, checking the completeness and accuracy of the CCBOM.
+
+This included areas such as:
+
+- components and materials
+- fasteners
+- manufacturing processes
+- assembly processes
+- material, process and tooling order
+- jigs and fixtures
+- cost estimates
+- carbon estimates
+
+The team should be prepared to explain how the component would actually be manufactured and assembled, rather than treating the CCBOM as simply a list of parts and values.
+
+### Wider Discussion
+
+Questioning then expanded beyond the selected components into the assumptions and methods used throughout the submissions.
+
+Topics included:
+
+- labour rates
+- indirect labour and overheads
+- material costs
+- cost drivers
+- carbon calculations
+- sourcing and transport assumptions
+- information within the [**Cost & Emissions Explanation Report**](../pre_comp_submissions/explanations_report.md)
+- submitted manufacturing drawings
+
+The exact direction of the discussion will depend on the judging panel and the answers given by the team.
+
+---
+
+## FTX7 Feedback
+
+### Content & completeness of BOM
+
+Score: `15/20`
+Penalty Points: `-3`
+Awarded Points: `12/20`
+
+```text
+CBOM was accurate and included most items. All parts were
+covered and in good detail. Jigs & Fixtures included.
+
+Missing Assembly of plenum to restrictor & couple processes
+wrong way around
+```
+
+### Realism of Cost Estimation
+
+Score: `20/30`
+
+```text
+Cost estimations were good. Labour rates were well thought out with different rates included for
+different skilled labour.
+
+Need to break out indirect labour but had fringe benefits. Overheads lacking most cost drivers
+apart from utilities and consumables - When quizzed managed as a team to come up with capital,
+depreciation, floor space, maintenance, consumables & Utilities
+```
+
+### Realism of Carbon Foot print Estimation
+
+Score: `8/15`
+
+```text
+They had carbon footprint explanation in a separate document. They had references of the
+sourcing across every part in the DBOM.
+
+Justification around carbon was poor and good be improved, including the main areas of the
+cradle to gate process - transport is it all plane or some shipped?
+```
+
+### Cost Understanding
+
+Score: `25/40`
+
+```text
+They had a moderate understanding of the cost drivers, needed a lot of coaching and guidance on
+overheads, SG&A & Profit. They had very good understanding material. Very good CBOM
+submitted, accurate, realistic costing, very detailed analysis
+```
+
+### Final Comments
+
+Total Score: `63/115`
+*(includes 5 pentalty points for extra document and 3 penalty points for missing items in CCBOM)*
+
+```text
+Very good CCBOM submitted. Good attitude by the team to a guidance and questioning. They all
+had involvement in cost however there wasn’t a designated cost lead - maybe should have one??
+
+BOM - Ok level of detail , tooling and jigs mentioned
+CEEF - Labour rates with extras included, Overheads, cannot see machine depreciation
+maintenance etc , check for this. CO2e explaination is quite detailed.
+SMF - good level of detailed drawings
+Team submitted an extra document outside of the requirement.
+```

docs/competition/statics/cost/pre_comp_submissions/CCBOM.md

@@ -0,0 +1,14 @@
+# Costed Carbonised Bill of Materials (CCBOM)
+
+The CCBOM should contain enough information for a factory to understand what must be purchased, manufactured and assembled to reproduce the car. It should describe a realistic build process rather than acting only as a list of parts and prices.
+
+Sequence matters. Within each assembly, list materials, manufacturing operations and assembly processes in the order in which they would actually occur (*don't put sanding after painting*). Check that every part, fastener, tool, jig and joining process required by the drawings is represented in the CCBOM.
+
+## Checklist
+
+- Structure the CCBOM so that the manufacturing and assembly sequence is easy to follow.
+- Include all parts, materials, fasteners, tooling, jigs and fixtures.
+- Include the processes used to join components and complete each assembly.
+- Check that quantities, materials and processes agree with the submitted drawings.
+- Confirm that cost and carbon data use consistent, justifiable assumptions.
+- Ask someone unfamiliar with the assembly to use the CCBOM and drawings to explain how it would be manufactured.

docs/competition/statics/cost/pre_comp_submissions/explanations_report.md

@@ -0,0 +1,3 @@
+# Cost & Emissions Explanation Report
+
+*details coming soon...*

docs/competition/statics/cost/pre_comp_submissions/index.md

@@ -0,0 +1,35 @@
+# Cost Report Documents
+
+A significant part of [Cost & Manufacturing Judging](../index.md) takes place before the competition, through a set of required submissions covering the cost, manufacture and carbon footprint of the car.
+
+The Cost Report Documents (CRD) consist of:
+
+- [Cost & Emissions Explanation Report](./explanations_report.md)
+- [Costed Carbonised Bill of Materials (CCBOM)](./CCBOM.md)
+- [Supporting Materials](./supporting_docs.md)
+
+---
+
+## Selected Area
+
+Early in the year, FSUK announces the area of the car that will be assessed in detail for Cost & Manufacturing. The required documentation should cover this area in extreme detail, as the specific components examined during judging are not revealed until the competition.
+
+For FTX7, the selected area was **Engine & Tractive System**, corresponding to the [**Powertrain**](../../../../ftx7/powertrain/index.md) department.
+
+---
+
+## Submissions
+
+The submissions are separate documents but they should be treated as parts of the same overall assessment. Information presented across the CCBOM, explanation report and drawings should be consistent and the team should be able to justify the assumptions and decisions contained within them.
+
+Particular attention should be paid to:
+
+- completeness and accuracy
+- realistic cost estimates
+- realistic carbon estimates
+- clear sourcing and justification of values
+- consistency between documents
+- compliance with the submission requirements
+
+**!!! warning: check the submission requirements !!!**  
+Only submit the documents required by the current year's rules. FTX7 received a **5-point pre-event penalty** for submitting an additional fourth document outside the required submission set.

docs/competition/statics/cost/pre_comp_submissions/supporting_docs.md

@@ -0,0 +1,3 @@
+# Supporting Materials
+
+*details coming soon...*

docs/competition/statics/design/design_for_manufacture.md

@@ -46,4 +46,8 @@ was poor.
 
 ## Team Debrief Notes
 
-**Add notes here:** Record verbal judging comments, questions asked, what evidence worked well, and what should be prepared earlier next year.
+**NOTE:** *These notes were recorded by team members immediately after judging. They summarise verbal comments and questions from the judges and should not be treated as official feedback.*
+
+- Define and record the manufacturing tolerances of the chassis jig rather than relying on nominal CAD dimensions.
+- Improve plywood jigging by using sufficiently thick material and locating repeated supports close to, but clear of, chassis nodes.
+- More expensive jigging, such as aluminium extrusion, should only be selected when its accuracy, adjustability or reuse provides enough benefit to justify the cost.