1. Nick Bloom Logan Kibler Philip Ritenour Scott Miner Matt Susa
Team “GT 1” Baja SAE - #48 car
Collegiate Design Series
Society of Automotive Engineers
Part 1/2
Nick Bloom
Logan Kibler
Philip Ritenour
Scott Miner
Matt Susa
EGR 481/482
Senior Design Progress Report
January 20, 2010

2. Overview of Presentation
Competition abstract & description
Goals
Cost & fundraising
Design
Remaining work
Acknowledgements
Questions

3. Competition Abstract
Exists “to simulate real-world engineering design projects and their related challenges.” (10.1, 2010 Baja SAE Rules)

4. Project Description
“Teams must design, build, test, promote, and compete with a vehicle within the limits of the rules.” (10.1, Rules)
Teams compete for manufacturing acceptance by a fictitious firm
Competition location:
Western Washington University
Bellingham, WA
May 19-22, 2010

5. Video
Clip from University of Louisville 2009 Baja SAE team (play 0:04 - 1:00)

6. 2010 Baja SAE - Dynamic Events

7. 2010 Baja SAE - Endurance Event

8. Competition Scoring Breakdown
2010 Western Washington Competition Scoring
Static Events (300 points)
Points
Design Report 50
Evaluation
100
Cost Report & Production Cost
Sales Presentation
Dynamic Events (700 points)
Acceleration 75
Hill Climb
Maneuverability
Rock Crawl
Endurance
400
Total
1000

9. Goals Design goals Performance goals 400 pound curb weight
12 inches of ground clearance
Short wheel base
Well-balanced
Durable
Performance goals
Successfully completing all events

10. Fundraising Efforts
IA office – engineering alumni mailing for Baja SAE, AISC Steel Bridge, and Solar Splash teams (~$1,000 raised for each)
IA office - targeted corporate mailing sent out (planning phone follow-up to these and many more companies)
Planning a t-shirt sale
Approaching GCSU for direct support

11. Competition Entrance Fee $1,000.00 Travel Expenses $3,750.00
Cost Estimate
Category
Amount
Competition Entrance Fee
$1,000.00
Travel Expenses
$3,750.00
Vehicle Parts & Fabrication
$4,750.00
Safety Equipment
$500.00
Grand Total
$10,000.00

12. Design Overview
Frame
Drive train
Suspension

13. Frame Design

14. Initial Decisions Examined other Baja vehicles for ideas
Fairmont State
Grove City
Oregon State
Simplistic frame geometry / compact nature of the vehicle.
Team has placed in the top 10 consistently, and won 1st place at last year’s regional competition.

15. Oregon State Baja SAE Vehicle

16. Purpose/Function Structural rigidity and stability to vehicle
Protects driver
Rollover injury
Significant impacts
Large suspended objects
Mounting location for seat and harness

17. Design Considerations
SAE specified parameters
Required members (i.e. lateral diagonal bracing, side impact member, under seat member)
Rear roll hoop width (≥ 29” at 27” above seat)
6” minimum clearance from top of helmet of tallest person to top of roll cage
Gusseting joints where continuous tubing is not used
Butt joints must be reinforced with welded sleeve

18. Design Considerations
Steel
Equivalent bending strength and stiffness of ASTM 1018 steel with 1” O.D. and .12” wall thickness (31.5)
Via calculations, determined sufficient replacement to be 4130 chromoly, 1.25” O.D. and .065” wall thickness

19. Design Considerations
Group specified considerations
Adequate width to accommodate hand clutch
Room for feet for accelerator and brake pedals
Proper seat mounting
Shocks, bumps, people’s legs falling asleep
Steel providers
McMaster Carr, OnlineMetals.com, O’Neil Steel, KenMac Metals, Steel Sales of Pittsburgh, Youngstown Pipe & Supply Co., Trinity Metals and Welding, Dillsburg Aeroplane Works
McMaster- $7.41/foot
OnlineMetals.com- $5.41/foot
Dillsburg Aeroplane Works- $2.38/foot

20. Design Considerations
Steel purchased
4130 steel tubing 1.25” OD, .065” wall thickness
4130 steel tubing 1.25” OD, .049” wall thickness
4130 steel tubing 1.25” OD, .035” wall thickness
Section states that only certain required members must have a minimum thickness of .065”; all others can be as small as .035”
Fabrication method: MIG (GMAW) Welding

21. Design Conception
Measurements taken by placing tallest driver in simulated driving position
Also used to integrate front suspension with front of body and pedals

22. Frame Concepts – RRH (1/2)

23. Frame Concepts – RRH (2/2)

24. Frame Concepts – RRH & Back

25. Frame Concepts – Drive System

26. Future Goals Finish design of front half of vehicle
Begin cutting, bending, welding, etc.
Mate frame to suspension components
Install engine and drive train components
Finish smaller details (pedals, controls, steering, etc.)

27. Design Future
Fairmont State University Baja SAE frame