Ben Gruenzner Nick Hanson Aaron Pilger Dustin Kalhoff Chris Kost Jason Kuenzli Justin Moe Scott Rector Mike Schmitz Jamie Schlachter Ryan Schommer Ryan Stebbins Paul Steevens Mike Tichy Faculty Advisors: Dr. Bruce Jones and Mr. Gary Mead Maverick Motorsports 2005 Car# 28

Purpose of the Event  Conceive, design, fabricate, and compete a formula-style car Low cost Easy to maintain Reliable High performance  Knowledge and creativity is challenged because of chassis and engine restrictions  Gain experience in a meaningful engineering team project

Competition Events Static Events Technical Inspection No points Cost and Manufacturing Analysis 100 points Presentation 75 points Design 150 points Total 325 points Dynamic Events Acceleration 75 points Skid Pad 50 points Autocross 150 points Fuel Economy 50 points Endurance 350 points Total 675 points

2005 MSU FSAE Goals  Manufacture a reliable car that will finish each FSAE event Simple design Easily manufactured and assembled  425 lb weight  Increased performance acceleration, braking, and handling  Create a documentation binder for future teams to follow  Better engine package  Improved driver positioning  Repeatable decision methods

Decision Matrix Wheel Decision MatrixWeightPerformance Cos tReliabilityBrake Line Routing Tota l Weighting57241 Keizer Mag Keizer Aluminum Sander Engineering D-Mount Real Wheels

Engine  Honda F4i 598cc 4-cylinder engine  Naturally aspirated  Converted to run on E-85 ethanol  Performance Electronics Engine Management System

Intake Design Single Plenum Design 19mm Restrictor Heimholtz Calculations

Exhaust Design Only Scott Knows

FSAE Dyno run 3

 6 speed, cockpit shifted manual transmission  Interchangeable drive Torque proportioning differential Direct drive aluminum spool  Custom RCV drive axles  Drive sprocket and chain driven Drivetrain

Chassis  MIG welded 1020 steel tubing and 1020 square tubing on the rear differential box  FEA Beam Structure Design engine as a semi-stressed frame member rear box removable for easy engine servicing  11.4” vertical center of gravity  48% Front / 52% Rear weight distribution  50%-50% left-right balance

Brake System  One dual piston caliper on each front wheel  One four piston caliper on the rear drive shaft  Two master cylinders: one to control the front brakes and one to control the rear brake

Steering System  12:1 Steering ratio  Less than 1/16” of Bump  30° of total steering  67% Ackerman Angle  Track width: 47” front and 45” rear

Suspension  Custom machined uprights and hubs  Double, unequal length A-arms  Pushrod actuated spring/damper  2.00” of total travel  SusProg3D software used to simplify component placement  66” wheelbase  Minimal camber change  Low roll center  Rising Spring rate

Upright Designs Aluminum FEA Design –FEA Picture

Tires and Wheels  13” x 6” Keizer spun aluminum rims are used allows more room for packaging chosen because of weight and cost  20X6.5-13” Tires Goodyear Slicks and Rain Tires

Documentation Design Report Document Binder

Vehicle Cost Brakes System Engine and Drivetrain Frame and Body Instuments and Wiring Miscelaneous Fit and Finish Steering System Suspension and Shocks Wheels and Tires Total

Any Questions?