BAJA SAE

E-tech Edition

Overview of the Problem

• Design/Build single-seat all terrain vehicle

• Adhere to rules outlined in 2013 Collegiate Design Series: Baja SAE Rules

Stakeholder’s Needs

• Finish in first place overall at the competition

• Efficient money-managing

• Having sponsors’ logos on the vehicle

Schedule at a Glance

Manufacturing Ideology

• Manufacture frame as a starting structure

• Manufacture suspension

• Manufacture mounts for components– Engine

– Transmission

– CVT

– Differential

• Manufacture smaller components for finishing touches

Fabrication and Operations

• Tube cutting

• Tube bending

• Tube coping

• Welding

• Grinding

• Drilling

• CNC machining

• Installed pre-fabricated components

Manufacturing Labor Costs

Frame

• Cut tubes to length

• All steel tubing was bent by hand using a manual pipe bender

• A mill was used for tube coping

• Tack welded then fully welded using MIG welder

Suspension

• Dual, unequal length A-arms

• Tubes cut to length

• Tubes bent to specified angles

• Mating ends of tubes coped or mitered

• Components fit into a jig and welded

– Prevents variation between suspension arms

Firewall

• The firewall is made out of sheet aluminum, it is very lightweight yet very strong

• Difficult to produce due to proper hole placement and folding over the edges

• Took three attempts to manufacture

Spill Plate and Gas Tank Cover

• Measure allowable area

• Layout cut/bend lines on sheet aluminum

• Cut and bend material

• Weld material where needed

• Weld on brackets

• Attach to frame with screws

Gas and Brake Pedal

• Manufactured out of aluminum bar stock

• Two independent master cylinder circuits

– One front

– One rear

• Separate brake light sensor for each circuit

• Brake on each front wheel

• Brake on rear final drive

Safety

• 5 point harness mounted safely to the rear roll hoop

• Fire extinguisher inside cockpit, mounted to firewall

• Chain guards

• Head restraint

• Head and body clearance

– 6in head, 3in torso and body

Electrical

• Brake light

• Reverse light and alarm

• Transponder attached to frame for timing

• Two properly mounted kill switches

– One mounted externally on the frame

– One within reach of the driver

Steering

• Steering guards manufactured from sheet aluminum

– Protection from legs being caught in steering knuckles and rack and pinion system

• Steel tie rods

• Approximately 2⁰ negative camber

• Zero toe

Body Panels

• Measured body areas which need covered

• Mocked up with cardboard

• Plastic panels were then cut to fit

• Riveted to welded tabs on the frame

• Numbers were attached to rear triangulation panels and nose panel

Results

• Tennessee Tech April 18-21

– Passed all three inspections

– Presented design and cost report

– Excelled in all dynamic events and endurance race

– Placed 14th Overall

• Next competition is May 16-19 in Washington

Results

Questions?