Mini Baja Advisory Presentation May 2, 2008

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1 Mini Baja Advisory Presentation May 2, 2008 Presenter: Mark Bell Accompanied by Baja Team 83 Member Jerrod Bohannon

2 Table of Contents Overview of Competition Design Conditions Grading Criteria Design Concepts Design Changes Drawings Manufacturing Analysis Schedule Financial Plan

3 Design Conditions Overall length must be a maximum of 108 Overall width must be a maximum of 64 Must be capable of carrying one person 6 3 tall and weighing 250 lbs. Must use Briggs & Stratton 10 hp OHV Intek Model

4 Cost Report Design Report Acceleration Braking Hill Climb Land Maneuverability Specialty Events Endurance Race Grading Criteria

5 Frame Design

6 Design Concepts Target vehicle weight: 450 lbs Forward, neutral, reverse transmission Design shifting mechanism

7 Design Changes Changed frame impact support tubing near firewall Modified trailing arm attach points Added tubing to enclose engine within frame Redesigned shock mounts once travel was finalized

8 Tubing Bender

9 Tubing Coping

10 Mig Welding

11 Waterjet Programming (Master Cylinder Tabs)

12 Trailing Arm Bearing Housing

13 Side View of Frame

14 Bearing Carrier

15 Routing Sheet Routing Sheet Customer s Name: Quantity: 2 OPERATION NO. DESCRIPTION OF OPERATION MACHINE TYPE TOOLING SET UP TIME (hr) OPERATION TIME (hr) MATERIALS 10 Cut off to length Power Hacksaw wall 1 x 1.5 x Finish grind cut end Grinding wheel Tape Measure to ensure proper length Cut off to length Power Hacksaw wall 1 x 1.5 x Cut chopped end to have 15 degree angle Power Hacksaw Finish grind cut end Grinding wheel Assembly NAME: Bottom Frame Rails Assembly NO: MB_As_83_ Square up tubing T square 70 Fixture with tabs TAC Weld Tabs/screws Weld Joints TAC Weld Clean up weld beads Hand Grinder INSPECTION Tape Measure Angle Finder Right Angle Ruler.08

16 Manufacturing Methods Primarily bent tubing with mig welded joints Heim joint inserts into tubing with mig welded joints End mill used to Cut keyways in drive shafts Finish machine front knuckles Lathe used to turn down Plastic inserts Shafts Machine bearing carriers

17 Manufacturing Methods cont. Hemsaw to cut rods to length Drill press to drill holes Taps to thread holes Water jet all tabs shock mounts drive plates outside front knuckle contour master cylinder tabs skid plate

18 Manufacturing Methods cont. Set up our own carbon fiber for body panels with help of Plastics Dept. Will have Plastics Dept. support with fabricating a spill pan and guards

19 Manufacturing Plan Lower Frame Cut tubes to length Cope ends to match other tubing Bend tubing at specified lengths and radii angles Tack weld all tubes into place Measure to assure the dimensions are correct Mig weld all joints to finalize assembly

20 Manufacturing Problems Shock Mounts Had to redesign for shocks mounting to frame Gussets had to be redrawn as well Front Knuckles Machined inner diameter too big for press fit of spindle Recut knuckles and outsourced for the press fit

21 Bearing Carrier

22 Front Impact Analysis

23 Side Impact Analysis

24 Rollover Analysis

25 Schedule Frame Suspension Finish weld chassis Nondriving components 14 Jan 4 Feb 11 Feb 18 Feb 15 Feb 3 Mar 5 May 29 May Polaris Parts Arrive Body Panels Lights / wiring Assembly of drivetrain Make spill pan Protective covers moving car Paint Graphics Roll bar padding Design Report Cost Report Competition Project Planning.xls 14 Jan 4 Feb 11 Feb 18 Feb 15 Feb 3 Mar 5 May 29 May

26 Financial Plan Mini Baja Financial Plan Fundraising procurred $ 2, Registration $ potential $ 5, Transmission $ Steel $ Polaris $ 1, Total Needed $ 9, Partial Total $ 2, Total Potential Fundraising $ 11, Total Needed ~ $ 9, Fundraised $ 5, Potential Fundraising $ 11, Total Costs $ 9, Financial Plan.xls

27 Conclusion Finish fixing front knuckles Final steer setup to get car driving Working toward finishing the vehicle: painting, carbon fiber panels, wiring, protective covers, graphics Going to competition Be competitive!

28 Questions?

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