Final Design Package

UNC Charlotte Senior Design Page 1 of 22Project: UNCC BAJ16 Final ReportAuthor: Thomas Pham Date: 2016-1-20

Cover Letter of TransmittalUNCC BAJA Team9201 University City Blvd.Charlotte, NC 28223

January 20, 2016

Senior Design Committee9201 University City Blvd. Charlotte, NC 28223

Senior Design Committee,

This report documents the design phase of the UNCC Baja SAE design competition. Baja SAE is an intercollegiate engineering design competition for undergraduate and graduate engineering students. The purpose of the project is to design and fabricate a prototype car to be sold to an interested company. The intended customer is a non-professional off-road enthusiast seeking a single seat, rugged, recreational vehicle. The design must be safe, easily transported and maintained, and most importantly fun to drive. Cost is an additional consideration, however higher cost is justified by higher performance and quality. Design effectiveness and performance will be evaluated in competition through a number of static and dynamic events. These events will include testing of the braking performance, acceleration, handling, and durability.

All designs are expected to conform to the 2016 Baja SAE international collegiate design competition rulebook. The vehicle is broken down into the following subsystems: chassis, suspension, and drivetrain. Rulebook regulates features including the chassis, track width, motor type, and etc. The motor required for this year is the Briggs and Stratton Intec 10 HP motor. Power from the motor passes through the wheels via custom CV axles. Each subsystem was designed with the intended use in mind, however due to unknown track conditions and geographic location, variability and adjustability were key factors in the design of the Baja car. The vehicle suspension includes multiple components chosen to reduce driver fatigue and improve simplicity. For example, Fox Float Evol 3 RC2 shocks were selected for their infinite adjustability and packaging. The front suspension of the vehicle utilizes a traditional double a-arm system that uses a knuckle from Yamaha YZF450R. The suspension system used in the rear of the vehicle is a three link, semi-trailing arm that uses a trailing arm that pivots on a heim in the front and is governed by two control links that affix to the rear of the trailing arm.

Considering a spot is obtained in a 2016 Baja competition, the UNCC team will be fully prepared to compete beginning in January. Fabrication will be completed and testing will begin. This will allow for further refinement of the design and optimization of the subsystems.


A directory containing all relevant project documents has been placed into a zip file and burned to two DVD’s. One DVD was delivered to our faculty mentor, and the other to the ISL Director. The folder name on the DVD that contains all files is UNCC_BAJ16_SD1.Deliverable File NameSummary of Project Description, Initial Performance Specification Document and Project Questions

UNCC_BAJ16_InitialPerformanceSpecification.pdf

Statement of Work Document UNCC_BAJ16_StatementOfWork_Rev3.pdfProject Specification Document UNCC_BAJ16_PerformanceSpec.pdfProject Plan UNCC_BAJ16_ProjectPlan_Rev2.mppConceptual Design Review Slides UNCC_BAJ16_CDR.pptxProgress Report #1 UNCC_BAJ16_ProgressReport1.pdfProgress Report #2 UNCC_BAJ16_ProgressReport2.pdfPreliminary Design Review Presentation UNCC_BAJ16.PDR.pptxFinal Timesheet UNCC_BAJ16_TimeSheet.xlsxBudget UNCC_BAJ16_Budget.xlxsBill of Materials UNCC_BAJ16_BOM.xlxs2016 SAE Mini Baja Rule Book 2016 Baja Rule Book.pdf

UNCC_BAJ16 Project – Final Design Package – Senior Design I


Date Revision Author Comments2015-12-8 A Thomas Pham Basic Layout, Chassis Info, Calculations2015-12-9 B Joshua Sweezy Brakes, Pedal Tray, Engine Mount2015-12-10 C Zane Yates Suspension, Drawings, Tires/Wheels2015-12-10 D Scott Carpenter Impact, Introduction

Table of Contents1. Overview of this Document.........................................................................................................42. Project Overview/ Statement of Work Summary........................................................................43. Specifications...............................................................................................................................4

3.1 General Requirements...........................................................................................................53.2 Performance Specifications...................................................................................................53.3 Performance Verification.......................................................................................................5

4. Design Narrative..........................................................................................................................64.1 Front Suspension...................................................................................................................64.2 Rear Suspension.....................................................................................................................6

4.2.1 Axles...............................................................................................................................64.3 Chassis...................................................................................................................................64.4 Gear Box................................................................................................................................74.5 Steering..................................................................................................................................74.6 Wheels and Tires/Brakes.......................................................................................................7

5. Impact..........................................................................................................................................86. Bill of Materials (BOM)..............................................................................................................97. Budget..........................................................................................................................................98. Conclusions..................................................................................................................................99. References....................................................................................................................................910. Appendices................................................................................................................................9

Appendix A: Bill of Materials....................................................................................................9Appendix B: Budget..................................................................................................................13Appendix C: CAD Drawings.....................................................................................................14Appendix D: Calculations..........................................................................................................19

1. Overview of this DocumentThis document contains all information relevant to the 2016 SAE Baja senior design project. The project involves designing a prototype vehicle for use in the 2016 SAE Baja competition.

UNC Charlotte Senior Design Page 4 of 22Project: UNCC BAJ16 Final ReportAuthor: Thomas Pham Date: 2016-1-20The prototype must outperform competitors in both static and dynamic events where judges assess the feasibility of the design and the prototypes are rigorously tested. The project is based around a hypothetical scenario where a manufacture is interested in purchasing a prototype to be added to their production line. The fictitious company has requested a single seat, off-road recreational vehicle that is easily transported and maintained.

The design work that has been completed to date, as well as issues that remain to be resolved are briefly described within this document. Additionally, an overview of communication between the team and the mentors is found below.

Thomas Pham, the project leader, is responsible for the maintenance of this document.

2. Project Overview/ Statement of Work SummaryThe objective of the project is to design and build a SAE regulation Baja car that will be used to compete in the 2016 Baja SAE Rochester or Tennessee competition. The Baja car must meet rules set forth by the Baja SAE Series and must be designed, built, and tested before the date of the competition in order to compete.

The activities that are accompanied with this project include designing, analyzing, fabricating, testing, and competing. Throughout the designing process, calculations, drawings, and models will be documented for the 2016 Baja SAE competition. Testing will be done after fabrication of the car is complete to prepare for the competition.

3. SpecificationsThe Baja car should be designed such that it will be able to compete in all dynamic events without major mechanical failures. The design should minimize weight while maximizing durability and maneuverability.

The main requirement of this project is to design and build a single-seat, all-terrain vehicle that sufficiently protects the driver. The Baja car should be able to overcome obstacles and perform well in all road conditions while providing excellent handling characteristics and driver comfort. Performance will be measured by success in the dynamics events which are described in the Baja SAE rules, and are subject to event-site weather and course conditions. The vehicle should out-perform competing companies in ruggedness, speed, handling, and off-road conditions.

3.1 General RequirementsRQ1: The general requirements for this project include the production of a new chassis with the use of SolidWorks.

RQ2: The front and rear suspension will also be redesigned with the help of Optimum Kinematics. A new front spindle and brake caliper design must also be evaluated.

UNC Charlotte Senior Design Page 5 of 22Project: UNCC BAJ16 Final ReportAuthor: Thomas Pham Date: 2016-1-20RQ3: The entire vehicle will conform to the SAE BAJA rule book.

RQ4: The vehicle will be designed and built by or before December 9, 2015.

RQ5: The cost for designing and manufacturing of the vehicle will remain at or below our budget of $8500

RQ6: The drivetrain will be optimized to provide maximum power and speed using the Briggs and Stratton motor provided.

RQ7: All parts will be designed using good engineering practices and designes will be backed up by calculations.

3.2 Performance SpecificationsPS1: Car must be able to compete in all different types of dynamic events consisting of acceleration, hill climb, land maneuverability, rock crawl, suspension, and endurance.

PS2: Car must have no more than a 64" track width and a desired wheelbase of no more than 108".

PS3: Car must be equipped with a Briggs & Stratton 10 hp OHV Intek engine.

PS4: Car will ideally weigh less than 450lbs excluding the weight of the driver.

PS5:Car will ideally have a suspension travel of 10 inches.

PS6:Car will ideally have a turning radius of 10 feet.

3.3 Performance VerificationV1: The car will be test rigorously before competition to verify PS1.

V2: The car will be measure with a metal tape measure to verify PS2.

V3: The car will be inspected before competition to verify PS3.

V4: The car will be weighed prior to competition to verify PS4.

V5: Suspension droop will be measured with no weight on wheels and then suspension will be measured with shocks bottomed out. The net length is the suspension travel.

V6: The car will be tested by turning around a curve with a radius of 10ft.


4. Design Narrative4.1 Front SuspensionThe front suspension was designed with an unequal length double a-arm wishbone configuration as seen in Appendix: A Figure 1 in order to improve road handling efficiency and ride quality. The rigid mounted arms allow little to no deflection during cornering to permit consistent alignment ratios. The unequal short-long arm configuration allows the system to experience negative camber gain, which ensures cornering stability at high speeds. Threaded ball joints will be used to connect the wheel uprights to the a-arms, which will also be used to adjust static camber. Static camber adjustments are key performance tuning techniques for various track conditions. Needle bearings will be used to mount the a-arms pivot axis to the chassis. Fox Float EVOL 3 RC2 air shocks will be used for the suspension due to their lightweight advantage and vastly adjustable progressive spring rate and damper controls. The air shocks have an available suspension travel of 5.8 inches. A motion ratio of 1.72:1 will be required in order to achieve 10 inches of total wheel travel.

4.2 Rear SuspensionThe rear suspension was designed to utilize semi-trailing arm links with four rear camber/toe links as seen in Appendix: A Figure 5. A trailing arm link was chosen in order to sufficiently package the rear end of the vehicle while maintaining limited axle plunge. Because the design of a trailing arm system allows the wheel to move in an arc parallel with the chassis as the suspension travels, the distance between the wheel and the chassis remains minimal thus reducing axle plunge. A trailing arm design also tends to slope back behind the vehicle and create an extended pivot axis for the wheel in relation to bumps in the road surface which also tends to reduce extreme shock loads. Threaded spherical rod ends will be used to mount the trailing arm pivot axis to the chassis and will be used for the wheel upright mounting points as well as the camber/toe link chassis mounting points.

4.2.1 AxlesThe axles are an important aspect of the car because they need to be durable, lightweight, and able to handle the torque of the engine. The axles also needed to be able to conform to the design of the rear suspension, such as axle plunge and track width. In previous years of Baja at UNCC it was also seen that making custom axles to fit the car and meet their needs was difficult. So in order to ensure that the axles would be strong and to correct the issue of plunge, our axles were custom made from the company CVJ axles. A slip axle was chosen in order to ensure that the axle plunge was corrected and was durable enough to withstand the events during competition.

4.3 ChassisBeing that the chassis is the largest subsystem, connects all the subassemblies together, and protects the driver, it is imperative that the chassis is strong enough, yet as light as possible. The

UNC Charlotte Senior Design Page 7 of 22Project: UNCC BAJ16 Final ReportAuthor: Thomas Pham Date: 2016-1-20chassis was designed based off the suspension points, and the guidelines of the 2016 SAE Mini Baja Rulebook and can be seen in Appendix: A Figure 3. The rulebook restricted how far certain members could be spaced from each other and where they were joined. There are two options for the type of material used for the primary tubing of the chassis. The primary members of the chassis must be constructed out of a 1” x 0.120” circular steel tubing and a carbon content of at least 0.18%. As an alternative, the chassis could be constructed out of a steel shape with a bending stiffness and bending strength exceeding that of a 1” x 0.120” circular steel tubing. The secondary members must be steel tubes having a minimum wall thickness of 0.035” and a minimum outside diameter of 1”.

The chassis was fabricated out of 4130-steel because of its high strength-weight ratio. The primary members were 1” x 0.065” while the secondary members were 1” x 0.035”. Placement of the suspension, seating, and drivetrain were taken into consideration when designing the chassis. After the preliminary design was finished, finite element analysis was ran on the chassis to determine the rigidity and weak points of the chassis.

4.4 Gear BoxThe gear box was designed to provide a strong torque at the rear wheels while also providing an acceptable top speed and the CAD drawing can be seen in Appendix: A Figure 4. As per the 2016 BAJA SAE rules each motor will be governed at a max of 3800 RPM. Because of this the gear ratio was decided to be 9:1, which will provide a top speed of 30 mph. This will allow for quick acceleration through tight turns and corners as well as a strong speed along straight parts of the course. The gear box will be manufactured out of 6061 Aluminum. The case will be CNC manufactured here at the Kulwicki Motorsports Lab. All gears and shafts will be outsourced for custom splining, gearing and heat treatment. The gear box will use Amsoil gear oil for cooling and lubrication. The gear box will be mounted behind the Briggs and Stratton power plant on the rear of the chassis. The gear box will connect to the motor on one end and transfer power to the CVT shafts on the other.

4.5 SteeringDue to the constrict timeline, the steering knuckles are the original manufacture equipment Yamaha YZF450R steering knuckles. To decrease user steering effort, the rack and pinion utilized is a Stilleto Fast Rack N Pinion. With a fast ratio of 6.4:1, this rack and pinion will decrease driver fatigue. This model features a new magnum housing design, which is 35% stronger than the previous model. The 2024-T4 aluminum housing increases the rigidity and torsional stiffness gives for better grear engagement in abusive conditions. This platform was chosen due to the YFZ450’s repeated success in the world of racing atv’s. For ease of manufacturing, the entire OEM brake caliper assembly from the YFZ450 was also chosen for the 2015-2016 Baja SAE car.

4.6 Wheels and Tires/BrakesThe wheels and tires to be used with the 2015 Baja SAE car will be a configuration of 22 inch ITP Mud Lite AT tires and 10-inch DWT Racing wheels. The tires were chosen specifically from

UNC Charlotte Senior Design Page 8 of 22Project: UNCC BAJ16 Final ReportAuthor: Thomas Pham Date: 2016-1-20a budget standpoint but also retain lightweight characteristics at 13.7 lbs each. The tires consist of a 6 ply design utilizing a unique center tread contact area to provide a smooth ride as well as plenty of traction. The wheels were chosen with particular offsets in mind to help achieve our desired track width. The hub assembly used was from a Yamaha YFZ450f sport atv. Due to time constraints the brakes from the YFZ450f will also be utilized. With a 6.5” drilled rotor and a dual 1” piston design, the brakes are more than sufficient for our application. With this brake setup a calculated 6 lbs of braking force is needed for the front while 18 lbs of baking force is needed for the rear. These values are strategically low for small amounts of fatigue while driving the 4-hour endurance event.

4.7 Pedal TrayThe pedal tray was designed for the highest possible strength to weight ratio. The material used was 6061 Aluminum. The tray is designed to mount to the chassis with custom sheet metal brackets. The tray will be able to adjust forward and reverse to accommodate various driver size. The pedal tray assembly can be seen in Appendix: A Figure 6. With a calculated max lock up force of 20lbs the aluminum pedal tray will be more than sufficient. Based on this number the pedal tray was designed with a safety factor of 10 to account for vibration, shock and fatigue of use. The brake pedal ratio is 3 to ensure low braking forces for the driver. This will reduce fatigue and ensure more consistent performance. All mounts are also made from 6061 Aluminum to ensure the lightest possible configuration. The pedal tray will be made on a CNC machine in the Kulwicki Motorsports Laboratory.

4.8 Engine MountThe focus of the engine mount is to provide a simple but effective mounting point of the Briggs and Stratton engine. The mount will be adjustable in the forward and reverse directions. This allows for the ability to adjust the belt tension without having to loosen the motor or move the mounts. The mount plate is made from 6061 Aluminum and will be made on a CNC machine in the Kulwicki Motorsports Laboratory. The engine mount will be slotted to fit the mounting configuration of the Briggs and Stratton power plant. The mount will move through turning of an ACME bolt with rotating flange nuts on each side. The mount will be guided on each side with precision steel shafts that ride on bronze bushings. A steel plate will be welded to the chassis on each side of the motor mount. The shafts and ACME bolt will feed through these plates to complete the mount. 5. ImpactDue to the nature of the baja senior design project, there are minimal regional and global implications, if any. However, within the university community, and especially among UNCC engineers, there is great potential for impact. The motorsports program’s reputation depends on its ability to prepare students for careers in racing, therefore, the extent of the impact depends, in part, on the success of the team. A successful car in the 2016 SAE Baja competition will add credibility to the UNCC motorsports program and prestige to the university. Future students competing in the Baja competition can use this foundation to improve their experience.

UNC Charlotte Senior Design Page 9 of 22Project: UNCC BAJ16 Final ReportAuthor: Thomas Pham Date: 2016-1-20We can further impact future baja teams by creating lasting relationships with sponsors. Sponsors provide financial support in exchange for recognition and publicity. When teams do well, sponsors gain more respect and acknowledgment. Financial support from sponsors reduces the monetary constraints of designing, enable the purchase of higher quality parts, and allow for more extensive and rigorous testing. By generating these relationships and subsequently performing well in competition, sponsors will continue to fund future baja teams.

6. Bill of Materials (BOM)The bill of materials for the 2016 SAE Baja project can be seen in appendix A.

7. BudgetThe budget for the 2016 SAE Baja project can be seen in appendix B.

8. ConclusionsThe UNCC Baja team is on schedule with the goal of competing in the SAE Baja competition in the next year. The team is working diligently towards the end goal, the competition, and we feel confident that we will be successful. Through the semester we were able to complete design of the car, and the fabrication of the chassis and suspension. Looking back, a lot was accomplished for this semester and put us in good standings for completing our goals for the next semester. In the future we will need to finish assembling the car for testing before the competition. Keeping on track will be the important for next semester in order to have adequate time for testing and repairs if required.

9. ReferencesGuiggiani, Massimo. The Science of Vehicle Dynamics Handling, Braking, and Ride of Road and Race Cars. Dordrecht: Springer Netherlands :, 2014.

Milliken, William F., and Douglas L. Milliken. Race Car Vehicle Dynamics. Warrendale, Pa: SAE, 1995.

Pacejka, Hans. Tire and Vehicle Dynamics. 3rd ed. Burlington: Elsevier Science, 2012.

10. AppendicesAppendix A: Bill of Materials

Item Quantity Price per Total SourceEngine Assembly 1 $600.76 $600.76 Sub-AssemblyTransmission Assembly 1 7178.5 $7,178.50 Sub-Assembly

UNC Charlotte Senior Design Page 10 of 22Project: UNCC BAJ16 Final ReportAuthor: Thomas Pham Date: 2016-1-20Suspension Assembly 1 3421.8 $3,421.80 Sub-AssemblySteering Assembly 1 706.02 $706.02 Sub-AssemblyFrame Assembly 1 192.4 $192.40 Sub-AssemblyBody Assembly 1 67.01 $67.01 Sub-AssemblyBrakes Assembly 1 1071.68 $1,071.68 Sub-AssemblySafety Assembly 1 249.75 $249.75 Sub-AssemblyElectrical Assembly 1 146.14 $146.14 Sub-AssemblyTotal 13634.06

ENGINE ASSEMBLYItem Quantity Price per Total Source

Engine 1 $468.23 $468.23 Briggs & StrattonFuel Filter 1 $5.99 $5.99 Briggs& StrattonFuel Cap 1 $49.00 $49.00 Briggs & StrattonOil 1 $3.19 $3.19 WalmartFuel Line 2 $2.24 $4.48 McMaster-CarrThrottle Cable 1 $9.89 $9.89 Phantom Racing

ChassisThrottle Pedal 1 $12.35 $12.35 In-HouseThrottle Linkage 1 $29.17 $29.17 Phantom Racing

ChassisDrip Pan 1 $10.23 $10.23 In-HouseSplash Shield w/ hose 1 $8.23 $8.23 In-HouseTotal $600.76

TRANSMISSION ASSEMBLYItem Quantity Price per Total Source

Drive Clutch 1 $889.00 $889.00 Gaged EngineeringCVT Belt 1 $129.50 $129.50 Gaged EngineeringCustom CVT Axles 2 $580.00 $1,160.00 CVJ AxlesGear Box 1 $5,000.00 $5,000.00 In-houseTotal $7,178.50

SUSPENSION ASSEMBLYItem Price Per Quantity Total Source

Rod Ends $18.00 10 $180.00 FK Rod EndsShocks $1250.00 2 $2,500.00 Fox Shox

UNC Charlotte Senior Design Page 11 of 22Project: UNCC BAJ16 Final ReportAuthor: Thomas Pham Date: 2016-1-20Steering Knuckle (Left) $118.48 1 $118.48 Yamaha DealerSteering Knuckle (Right) $118.48 1 $118.48 Yamaha DealerBolt Caliper to Knuckle $1.67 4 $6.68 Yamaha DealerHub (4x156) $38.66 2 $77.32 Yamaha DealerWheel Cover Plate $2.96 2 $5.92 Yamaha DealerHub bolt $2.14 8 $17.12 Yamaha DealerBearing Spacer $5.66 2 $11.32 Yamaha DealerBearing $13.88 2 $27.76 Yamaha DealerOil Seal $5.59 2 $11.18 Yamaha DealerCollar $8.35 2 $16.70 Yamaha DealerPlate Washer $2.50 2 $5.00 Yamaha DealerWheel Bearing (outside) $14.12 2 $28.24 Yamaha DealerOil Seal (Outside) $4.29 2 $8.58 Yamaha DealerCollar (Outside) $3.62 2 $7.24 Yamaha DealerWasher Plate (Outside) $1.72 2 $3.44 Yamaha DealerCastle Nut $3.28 2 $6.56 Yamaha DealerPivot Works Bearing Kit $81.99 2 $163.98 American StarUpper And Lower Ball Joints

$26.95 4 $107.80 Yamaha Dealer

Knuckle Rear $101.99 2 $203.98 Polaris DealerWheel Bearing $32.99 2 $65.98 Polaris DealerC-Ring $2.31 2 $4.62 Polaris DealerNeedle Bearing $12.99 6 $77.94 Polaris DealerSeal $4.30 8 $34.40 Polaris DealerThrust Washer $1.47 8 $11.76 Polaris DealerUpper control Shaft $10.99 2 $21.98 Polaris DealerLower control shaft $19.99 2 $39.98 Polaris DealerNut $1.08 4 $4.32 Polaris DealerUpper Bolt $5.38 2 $10.76 Polaris DealerLower Bolt $5.19 2 $10.38 Polaris DealerSleeve Float 17.5 2 $35.00 Polaris Dealer1/2''x20-4'' Bolt $6.04 2 $12.08 McMaster Carr1x.065 Weldable tube ends $18.00 10 $180.00 McMaster Carr1/2''x20-2'' Bolt $4.90 2 $9.80 McMaster CarrTotal $3,421.80

STEERING ASSEMBLY


Item Quantity Price per Total SourceHiem Ends 6 $18.23 $109.38 McMaster-CarrBushings 1 $6.36 $6.36 McMaster-CarrSteering Wheel 1 $35.97 $35.97 OMPQuick Release 1 $24.99 $24.99 Speedway MotorsRack and Pinion 1 $499.99 $499.99 StilettoTie Rods 2 $11.19 $22.38 In-HouseClevis 2 $1.23 $2.46 In-HouseSteering Shaft 2 $2.00 $4.49 In-HouseTotal $706.02

FRAME ASSEMBLYItem Quantity Price per Total Source

Complete Roll Cage 1 $66.45 $66.45 In-HouseSuspension Mounts 14 $1.00 $14.00 In-HouseBrake Mounts 2 $1.00 $2.00 In-HouseCut Out Firewall 1 $15.32 $15.32 In-HouseEnd Caps 8 $0.24 $1.92 In-HouseBody Tabs 8 $0.35 $2.80 In-HouseSeat Mounts 4 $1.25 $5.00 In-HouseTransmission Mounts 2 $14.45 $28.90 In-HouseFire Extinguisher Mount 1 $1.35 $1.35 In-HouseSeat 1 $54.66 $54.66 In-HouseTotal $192.40

BODY ASSEMBLYItem Quantity Price per Total Source

Skid Plate 1 $30.89 $30.89 In-HouseSide Panels 2 $8.96 $17.92 In-HouseNumber Panel 2 $2.24 $4.48 In-HouseRear Panels 2 $4.23 $8.46 In-HouseFront, Dash Panel 1 $5.26 $5.26 In-HouseTotal $67.01

BRAKE ASSEMBLYItem Quantity Price per Total Source

UNC Charlotte Senior Design Page 13 of 22Project: UNCC BAJ16 Final ReportAuthor: Thomas Pham Date: 2016-1-20Brake Calipers - Front 2 $223.00 $446.00 Yamaha DealerBrake Calipers - Back 1 $223.00 $223.00 Yamaha DealerBrake Rotor - Front 2 $26.88 $53.76 Yamaha DealerBrake Rotor - Back 1 $26.88 $53.00 Yamaha DealerBrake Fittings 4 $4.25 $17.00 SummitBrake Lines - Front 2 $23.00 $46.00 SummitBrake Lines - Back 1 $32.00 $32.00 SummitMaster Cylinder 2 $85.00 $170.00 BremboBrake Fluid 1 $3.24 $3.24 WalmartHardware 1 $15.23 $15.23 McMaster CarrBrake Pedal 1 $12.45 $12.45 In houseTotal $1,071.68

SAFETY ASSEMBLYItem Quantity Price per Total Source

Seat Belts 1 $69.95 $69.95 SafequipFire Extinguisher 2 $24.95 $49.90 Gaged EngineeringFire Extinguisher Activator 2 $64.95 $129.90 Scott DrakeTotal $249.75

ELECTRICAL ASSEMBLYItem Quantity Price per Total Source

Wire / Connectors 8 $0.69 $5.52 McMaster-CarrBattery holder 1 $4.15 $4.15 Parts ExpressKill switch 2 $25.12 $50.24 PolarisBrake light switch 2 $26.23 $52.46 PolarisBrake light 1 $20.95 $20.95 Amazon100' 16 gage wire 1 $11.23 $11.23 Radio ShackBattery 1 $1.59 $1.59 Radio ShackTotal $146.14

Appendix B: BudgetBUDGET

Category/Item Quantity Price Per TotalDevelopment Materials

$0.00$0.00


$0.00$0.00

BOM Materials for demonstration

$0.00

From Top Level of

BOM

$13,634.06

Parts and Materials Total

$13,634.06

LaborStudent Time

500 $100.00 $50,000.00

Mentor Time

50 $150.00 $7,500.00

Sponsor Time

$150.00 $0.00

Total Labor $57,500.00Total Parts, Materials, and Labor $71,134.06

Appendix C: CAD Drawings


Figure 1: Front Lower Control Arm


Figure 2: Front Upper Control Arm


Figure 3: 2015-2016 Baja SAE Chassis


Figure 4: Transmission Gear Box and Components


Figure 5: Suspension Trailing Arm

Figure 6: Brake Pedal Tray Assembly

Appendix D: Calculations




Documents

Final Design Package