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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
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
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