Department of Mechanical and Materials Engineering

Florida International University, Miami, FL

EML 4551

A SENIOR DESIGN PROJECT
PREPARED IN PARTIAL FULFILLMENT OF
THE REQUIREMENT FOR
THE DEGREE OF
BACHELOR OF SCIENCE
IN
MECHANICAL ENGINEERING

Team Mini Baja
Final Report

Submitted by:
______________
Jorge Posada
Team Leader
______________
Richard Badali
______________
Elena Pizano
______________
Avi Sharir
______________
Nick Gimbel
______________
Ricardo Urbina
__________________
Faculty Advisor
Dr. Ibrahim Tansel

April 15, 2007

1
Table of Contents
List of Tables and Figures....................................................................................................... 2
Team Statement.......................................................................................................................... 3
Ethical Design Statement ........................................................................................................ 3
Environmental Impact Statement .......................................................................................... 3
Project Statement ...................................................................................................................... 3
Literature Review....................................................................................................................... 4
Design Phase................................................................................................................................... 7
Design Specifications............................................................................................................... 7
Functional Specifications........................................................................................................ 8
Proposed Design Summary .................................................................................................... 9
Drawing Tree ............................................................................................................................. 11
Bill of Material and Preliminary Cost Analysis (BOM) ................................................... 12
Failure Modes and Effects Analysis (FMEA) .................................................................... 13
Engineering Analysis Summary........................................................................................... 16
Project Timeline and Task Breakdown .............................................................................. 17
Frame Design............................................................................................................................ 18
Rear Suspension...................................................................................................................... 25
Flotation...................................................................................................................................... 27
Transmission............................................................................................................................. 29
Build Phase ................................................................................................................................... 30
Team Meetings and Progress............................................................................................... 30
Testing........................................................................................................................................... 46
Appendix A: Sponsorship Proposal .................................................................................. 52






2
List of Tables and Figures
Table 1 ............................................................................................................................................ 8
Figure 1........................................................................................................................................... 9
Figure 2......................................................................................................................................... 10
Table 2 .......................................................................................................................................... 12
Table 3 .......................................................................................................................................... 15
Figure 4......................................................................................................................................... 17
Table 4 .......................................................................................................................................... 19
Figure 5......................................................................................................................................... 20
Figure 6......................................................................................................................................... 21
Figure 7......................................................................................................................................... 22
Figure 8......................................................................................................................................... 23
Figure 9......................................................................................................................................... 24
Figure 10....................................................................................................................................... 24
Figure 11....................................................................................................................................... 25
Figure 12....................................................................................................................................... 26
Figure 13....................................................................................................................................... 27
Figure 14....................................................................................................................................... 28
Figure 15....................................................................................................................................... 28
Figure 16....................................................................................................................................... 28
Figure 17....................................................................................................................................... 30
Figure 18....................................................................................................................................... 31
Figure 19....................................................................................................................................... 33
Figure 20....................................................................................................................................... 34
Figure 21....................................................................................................................................... 35
Figure 22....................................................................................................................................... 35
Figure 23....................................................................................................................................... 36
Figure 24....................................................................................................................................... 36
Figure 25....................................................................................................................................... 37
Figure 26....................................................................................................................................... 37
Figure 27....................................................................................................................................... 38
Figure 28....................................................................................................................................... 39
Figure 29....................................................................................................................................... 39
Figure 30....................................................................................................................................... 40
Figure 31....................................................................................................................................... 40
Figure 32....................................................................................................................................... 41
Figure 33....................................................................................................................................... 41
Figure 34....................................................................................................................................... 42
Figure 35....................................................................................................................................... 42
Figure 36....................................................................................................................................... 43
Figure 37....................................................................................................................................... 43
Actual detail of cost: ..................................................................................................................... 56

3
Team Statement

We are a dedicated group of students seeking a Bachelor in Science of Mechanical
Engineering that share a passion for motor sports and outdoors activities. We will design keeping
in mind concepts for Fit, Form and Function while being able to comply with all of the
requirements that SAE has laid out in order to create a functional yet safe and reliable vehicle.

Ethical Design Statement

This project is being executed and analyzed in accordance to the NSPE Code of Ethics
for all purposes of design and prototyping of all components and assemblies that will be created
as part of this design concept.

Environmental Impact Statement

The design and testing of the prototype is being manufactured in such manner that the
impact that it will have to the surrounding environment is minimum and has no permanent
adverse effects on the community.

Project Statement

The SAE Mini Baja competition includes over 120 teams from various universities who
design, build, and compete in Mini-Baja style off-road vehicles that must survive rough terrain
and water. This competition focuses on the chassis and suspension design of the car, restricting
the motor to a standard ten horsepower Briggs and Stratton. We are challenged to design a
rugged and reliable off-road capable car, while still keeping cost and maintenance affordable for
the theoretical consumer. Competition is focused on the design and innovation of cost effective
parts, as well as dynamic events that test the real world function of these vehicles. The cars must
follow strict safety and cost regulations, making the design of these cars challenging for student
engineers.


4
Literature Review

[1] Beer, F., Johnston, R., and Dewolf, J., 2006, Mechanics of Materials, McGraw-Hill
Companies, Inc.

[2] Shigly, J., Mischke, C., and Budynas, R., 2004, Mechanical Engineering Design, McGraw-
Hill Companies, Inc.

This textbook used in many of our classes is an excellent source. From understanding
load and stress analysis to failure resulting from loading, the book gives us all the tools necessary
to design our vehicle. The Mini-Baja vehicle is a project that is started from scratch and thus all
the different components must be analyzed and computed. This textbook gives us many of the
formulas and techniques we need to construct our vehicle.

[3] Nelson, C.A., and Davis, T.B., 2004, Millwights and Mechanics Guide, Wiley Publishing,
Inc.

[4] Miller, R. and Miller, M.R., 2004, Machine Shop Tools & Operations, Wiley Publishing,
Inc.

[5] Den Hartog, J.P., 1977, Strength of Materials, Dover Publications, Inc.

[6] Oberg, E., Jones, F.D., Horton, H.L., and Ryffel, H.H., 2004, Machinerys Handbook,
Industrial Press, Industrial Press, Inc.
[7] Vickers, M., 2006, Smooth Ride: ATV Suspension Market Report,http://www.atv-
industry.com/features/may06/suspension/index.html.
[8] Gears Manufacturers, http://www.gears-manufacturers.com/.
[9] West Coast Differentials, http://www.differentials.com/.
[10] Gillespie, T.D., 1992, Fundamentals of Vehicle Dynamics, SAE International.
[11] Dempsey, P.K., 1994, How to Repair Briggs and Stratton Engines, McGraw-Hill
Professional.
The book How to Repair Briggs and Stratton Engines is one of the top five sources of
the 20 sources we found as a group. This source is important to the success of our project
because it will help us perform better with the Briggs & Stratton engine which is to be used in
this SAE competition. It will give us an advantage both when working on putting the engine
together with the car and once we are at the competition if some repair needs to be done to the
engine, we have the manual. The topics covered in the book are as follows: Introduction Safety
5
Considerations, The Product Range, Troubleshooting, Ignition Systems, The Fuel System,
Starters, Charging Systems, and Engine Mechanics. With this in our hands our knowledge of the
engine will be at its best.
[12] RockCrawler.com, http://www.rockcrawler.com/.
[13] Dixon, J.C., 1999, The Shock Absorber Handbook, SAE International.

[14] SAE Gear and Spline Technical Committee, Gear Design Manufacturing and Inspection
Manual, SAE International.
[15] Arrowhead: Custom Fiberglass Molding and Plastic Vacuum Forming,
http://www.arrowheadinc.com/.

[16] Petroski, H., 2006, Success Through Failure, Princeton University Press.

Success Through Failure shows us that making something better by anticipating failure
is what invention and design are all about. This book shows that all designs have some form of
failure. The Mini-Baja has many different design choices. Understanding that a good design is
one that has failed several times, we can build a better vehicle than our former team. This book
gives us the confidence to build and design a Mini-Baja vehicle with the understanding that
failure is part of the process.

[17] Staniforth, A., 1999, Competition Car Suspension: Design, Construction, Tuning, Haynes
Publishing.
The team thinks that this particular component to the integrity and reliability of the car
are extremely important, not only to the design portion of this system, but also to the proper
selection of the adequate components to make this system. Even though there are many aspects
for designing a suspension, only those aspects that relate directly to the scope of this project will
be considered and thus further investigation about such components must be performed. Since
the team has a time constraint issue due to the amount of time there is before the competition, we
as a team are trying to identify those aspects of the design that are of the utmost importance so
that the proper time management can be allocated to this components.
[18] Donkin, C., 1935, The Elements of Motor Vehicle Design, Oxford University Press.

[19] Barker, R., and Harding, A., 1992, Automotive Design, Pennsylvania: Society of
Automotive Engineers.
6

[20] Twigg, P., 2004, The Science of Motor Vehicle Design, Elsevier Limited.

The Science of Motor Vehicle Design textbook is a great source because it contains all
of the engineering used in the process of designing a car. It combines the sciences required and
the actual parts of a car. For example, in Chapter 2, it explains forces and moments, and then in
the last section it describes the design of framework with regards to the forces studied in the
previous section. Its content includes everything from distortion of materials, motion, power,
work, thermodynamics, metals, electricity, and control and instrumentation. Since we will be
designing and assembling the Mini-Baja car from scratch, this book will be a great guide for us.

[21] Nickless, S., 1993, The Anatomy & Development of the Formula Ford Racecar,
Wisconsin: Motorbooks International.

[22] Car Design Online, www.cardesignonline.com.

[23] Rao, S., 2003, Mechanical Vibrations, Prentice Hall.


7
Design Phase

Design Specifications

Vehicle Design
Attractive to customers
Easily operated
Easy to manufacture and maintain
Safety to the highest degree
Dimensions and Configurations
Have four or more wheels
Carry one person 190 cm (63) tall weighing 113 kg (250 lbs) at minimum
No more than 162 cm (64 in) at the widest point
No maximum length for vehicle; however, SAE recommends the car be no longer than
108 in. in length
Capability
Safe operation over rough land terrain, including but not limited to rocks, sand, jumps,
steep inclines, mud and shallow water
Safe operation over any type of weather including but not limited to rain, snow, or ice
Adequate ground clearance, minimum 8 inches
Amphibious, able to move over water

Engine
Briggs & Stratton 10 hp OHV Intek Model 205432 Type 0035-el

Vehicle Identification
Transponder
Team number
School name/initials
Sponsor Logos
o Briggs and Stratton
8
o SAE
o Other sponsors
Functional Specifications
This portion of the design describes the objective of the project as the function. The sub-
functions of this project describe the constraints set forth by the Society of Automotive
Engineers, the engineering authority proposing the competition. The means of the functional
analysis describes the processes that were considered in the design of the Mini-Baja.

Function Sub function Means 1 Means 2
The frame must withstand a
minimum additional weight of 250
pounds and must accommodate a
person with a height of 6'3".
A strong frame


Max. Allowable length
and width
The drive train must be durable
and effective enough to transfer the
power from the engine to the
wheels under harsh conditions and
rugged terrain, including but not
limited to rocks, sand, jumps, steep
inclines, mud and shallow water.
A two speed
transmission that allows
for a high torque and
high horsepower.


CVT, gear ratio selection
The suspension of the prototype
must travel enough to provide
maximum clearance on a hill
climb, maintain stability in harsh
road conditions, provide maximum
transfer of power and maintain
center of gravity.
Bolting the front wheels
to a pair of A-arms and
the rear two trailing
arms to provide a
reasonable suspension
travel in off road
conditions.
Selecting the optimal
suspension settings,
spring and damping
rates.
The steering of the prototype must
be durable enough to withstand
some flying objects and the ratio
between the steering wheel and
tires must provide a quick transfer
from lock to lock and allow the
driver to keep the prototype
straight at high speeds on rugged
terrain.
A steering wheel will
input the motion into
the steering column
transferring the motion
through the rack and
pinion to the CV joints

Connecting steering
wheel assembly directly
to the front wheel hubs.
Design and build a
prototype of a rugged
single seat, off-road
vehicle
The components of the car must be
in a way to allow the driver to exit
within 5 seconds, components such
as throttle and brake levers must be
adjustable to accommodate various
sized drivers, and the driver and
certain components of the
prototype must be protected from
flying debris.
A safety harness and
bucket seat to maintain
the driver securely
while riding, with a roll
cage and full floor.


Quick release steering
wheel to provide
adequate clearance in
exiting vehicle.
Table 1
9
Proposed Design Summary
The figures below are the drawings of the suspension and frame of the Mini-Baja. Figure 1
shows the different views for the A-Arm Suspension system that was designed to be incorporated
into the Mini-Baja. Figure 2 shows the structural frame (external sheet metal not present in
drawing for a more complete view) that is going to be used in the production of the Mini-Baja.


Figure 1

10

Figure 2




11
Drawing Tree

In this portion of the design the design of the different components of the proto-type are
broken down into different categories to keep a more efficient record of the different physical
parameters of the system in order to overcome the obstacles that will be set by SAE.



































Structural
S
Drive Train
DT
Suspension
SU
Steering
ST
Design Project Org.

Frame
SF
Brackets
SF2
Joints
SF1
Supports
SF3
Engine
DTE
CVT (Torque
Converter)
DTC
Transmissio
n
Springs
SU1
A-Arms
SU3
Shock
Absorbers
SU2
Trailing
Arms
SU4
Rack &
Pinion
ST1
Steering
Column
ST3
CV Joints
ST2
Steering
Wheel
ST4
Project
Concepts
Final Report
Progress
Reports
Final
Presentation
Mini Baja Competition 2006
Figure 3
12
Bill of Material and Preliminary Cost Analysis (BOM)
The table below describes lists the different parts required in the Mini-Baja in order to achieve an
efficient design. The table also describes the aspects of the Mini-Baja that it will be used in,
whether it needs to be made or bought, the material its made from, the vendor, and the cost of
getting the material needed from its retailer to in order to construct the prototype.



Table 2




13
Failure Modes and Effects Analysis (FMEA)

Due to the vast quantity of separate parts in the Mini-Baja the failure modes were broken
down into separate categories (e.g. mechanical, structural, etc.). The structural failures of the
Mini-Baja were deemed to have the greatest priority considering its function, to protect the
driver from oncoming debris, in some cases the driver him/herself, and it is the platform on
which the entire system is mounted. The second most critical aspect to the design would be the
safety failures.


Item Name
Failure
Mode
Failure
Cause
Operation
Effects/
Hazard
Safety
Effects/Hazards Safeguards/Backups Actions
Frame
Structural /
Safety
Too much
load or
shock
applied
leading to
excess axial
stress
The frame
bends or
breaks
The driver could
fall out of the
Mini-Baja
leading to
serious injury or
death
Relatively high factor
of safety to ensure
structural integrity
Relatively high
factor of safety and
diligent testing
Hardware Structural
Too much
load or
shock
applied
leading to
excess axial
stress
Mechanical
and structural
components
damaged
leading to
inability of use
Can lead to
serious injury or
death
Relatively high factor
of safety to ensure
structural integrity
Relatively high
factor of safety and
diligent testing
Brackets Structural
Excess load
or vibration
causing
excess
bearing and
yielding
stress
Mechanical
and structural
components
damaged
leading to
inability of use
Can lead to
serious injury or
death
Relatively high factor
of safety to ensure
structural integrity
Relatively high
factor of safety and
diligent testing
Supports Structural
Too much
load or
shock
applied
leading to
excess axial
stress
Structural
damage
leading to
inability of use
Can lead to
serious injury or
death
Relatively high factor
of safety to ensure
structural integrity
Relatively high
factor of safety and
diligent testing
Flotation
Material Materials
Lack of
structural
integrity Mini-Baja sinks
Driver could
drown
Relatively high factor
of safety to ensure
structural integrity
Relatively high
factor of safety and
diligent testing
Engine Mechanical
Lack of clean
air and fuel
to maintain
operation
Possibility of
explosion;
inability to
operate
Can lead to
serious injury in
explosion case
Placement in area to
minimize risk to driver N/A
14
CVT Mechanical
Lack of
structural
integrity
under cyclic
loading
Inability to
operate N/A
Relatively high factor
of safety to ensure
mechanical integrity Diligent Testing
Transmission Mechanical
Lack of
structural
integrity
under cyclic
loading
Inability to
operate N/A
Verification of desired
specifications of
component Diligent Testing
A-Arms Mechanical
Too much
load or
shock
applied
leading to
excess axial
stress
Suspension
compromised
Can lead to
serious injury
Relatively high factor
of safety to ensure
mechanical integrity
Relatively high
factor of safety and
diligent testing
Trailing Arms Mechanical
Too much
load or
shock
applied
leading to
excess axial
stress
Suspension
compromised
Can lead to
serious injury
Relatively high factor
of safety to ensure
mechanical integrity
Relatively high
factor of safety and
diligent testing
Springs Mechanical
Wrong
spring
chosen for
application
Suspension
compromised
Can lead to
serious injury
Diligent testing to
ensure functionality
Relatively high
factor of safety and
diligent testing
Shock
Absorbers Mechanical
Debris
damaging
component
Suspension
compromised
Can lead to
serious injury
Verification of desired
specifications of
component Diligent Testing
Rack & Pinion Mechanical
Obstruction
in travel of
system
Inability to
steer N/A
Verification of desired
specifications of
component Diligent Testing
CV Joints Mechanical
Excess
torque
applied
Inability to
operate N/A
Verification of desired
specifications of
component Diligent Testing
Steering
Column Mechanical
Debris
damaging
component
Inability to
steer
Can lead to
serious injury
Relatively high factor
of safety to ensure
mechanical integrity
Relatively high
factor of safety and
diligent testing
Brake System
Kit Mechanical
Inability to
provide
sufficient
braking force
Extensive
damage to
Mini-Baja in
undesired
scenario
Can lead to
serious injury in
undesired
scenario
Diligent testing to
ensure functionality
Relatively high
factor of safety and
diligent testing
Pedals Mechanical
Excess load
applied by
driver to
component
Inability to
operate
Can lead to
serious injury in
undesired
scenario
Relatively high factor
of safety to ensure
mechanical integrity
Relatively high
factor of safety and
diligent testing
Steering
Wheel Mechanical
Excess load
applied by
driver to
component
Inability to
steer N/A
Verification of desired
specifications of
component Diligent Testing
15
Transponder Electrical
Water
damage to
component
Disqualification
of competition
Can cause
electric shock
Insulation to avoid
shock driver Diligent Testing
Driver Seat Safety
Excess load
leading to
bearing yield
Driver's safety
compromised
Can lead to
serious injury of
driver
Diligent testing to
ensure functionality
Warning placed on
frame of weight
range
Tires Mechanical
Puncture by
debris
Inability to
operate N/A
Verification of desired
specifications of
component Diligent Testing
Rims Mechanical
Damaged by
debris
Inability to
operate N/A
Verification of desired
specifications of
component Diligent Testing
Radio Kit Electrical
Water
damage to
component
Disqualification
of competition
Can cause
electric shock
Insulation to avoid
shock driver Diligent Testing
Goggles Safety
Damaged by
debris
Disqualification
of competition
Can cause
serious injury
Verification of desired
specifications of
component N/A
Gloves Safety
Cuts caused
by sharp
edges of
Mini-Baja N/A Can cause injury
Verification of desired
specifications of
component N/A
Helmet Safety
Damaged by
debris N/A
Can cause
serious injury or
death
Verification of desired
specifications of
component N/A
Wrapping
Foam Safety
Damage
during
transport
Aesthetical
damage N/A leave alone N/A
Fire
Extinguisher Safety
Lack of
maintenance
Can lead to
excess fire
damage
Can lead to
serious injury Constant checking N/A
Flotation
Device Mechanical
Lack of
buoyancy Mini-Baja sinks
Driver could
drown
Diligent testing to
ensure functionality Diligent Testing
Table 3


16
Engineering Analysis Summary


Stress & Strain Analysis of the Frame
The frame must be checked for the stress and strain exerted as a result of static and dynamic
forces, forces that may come from bending moments due to the torque transferred by the drive
train will be exerting on the support point, forces and bending moments due to impact and due to
car dynamics. The analysis will determine the maximum allowable stress and reactions at joints
along the frame, also providing insight of the weakest portion of the design due to contours or
geometric shape; ultimately discovering those portions of the frame that lack support. This will
also aid determine the thickness of the tube and the rigidity of the frame while the forces are
being exerted.

Analysis of Suspension Components
The suspension system is dependant on three main factors force magnitude, dampening ratios,
and kinematics analysis of the control arms as they interact with the rest of the suspension
components. The analysis will determine the maximum allowable force magnitude the control
arms can handle before failing (failing due to bottoming out, fracture or over damped system),
the correct spring rate and damper combination will be determined through a combination of
simulated analysis and actual testing of the components; ultimately finding the optimal range of
suspension travel.

Gear Analysis for Drive Train Selection
The selection of the gear system is important to maximize the transmission of power from the
engine to the rear wheels. The result of the analysis will determine the amount of power and
torque applied to the wheels.

Buoyancy of the Flotation Device
The buoyancy force of the vehicle must be determined in order to find the optimal depth of the
vehicle submerged in water. The critical parameters would include the maximum weight of the
vehicle and its weight distribution. These parameters are required to verify the correct volume,
distribution, and type of flotation material.
Project Timeline and Task Breakdown



Figure 4




Frame Design
The purpose of the frame is to create a three dimensional space for the driver to fit within
the steel roll cage while driving the car and still be in a safe environment. SAE provides all
teams with a list of requirements that must be met in order to pass the technical inspection that
the car will be subjected to upon initiation of competition activities. The requirements to be met
range from material constraints to space limitations, making the material and solid model
challenging to design, all of these conditions must be met while keeping in mind off road race
cars concepts such as horsepower to weight ratio, cars center of gravity, ground clearance,
vehicle dynamics, height, width and length amongst many other concepts.

With this head start the material selection was originally made. In off road race car
construction there are only a few common materials used due to factors such as cost, machine
ability, density, hardness and materials properties such as tensile strength and modulus of
elasticity. SAE also provides a list of minimum requirements that must be met for the material,
namely they are the bending stiffness and bending strength that have to be calculated about an
axis that gives the lowest value.

Since the bending stiffness is directly proportional to the EI product of the material and
the bending stiffness of the material is given by equation (#), only those parameters that will
have an effect on the strength and integrity of the frame will be considered for the material
selection of the tubing. Since the weight of the car must also be considered to be a limiting factor
for the material selection as well, the material density will also be compared against the
previously selected materials in order to optimize the selection while keeping in mind the price
of the raw material. The material selection is summarized on table (#) which contains all relevant
information such as yield strength, Youngs modulus of elasticity, material density and cost per
foot for three different types of steel, AISI 1018, AISI 1020 and AISI 4130.
c
I S
y
Equation (#)




19
Where:
E = The modulus of elasticity.
I = The second moment of area for the
cross section about the axis giving the
lowest value.
Sy = The yield strength of material in
units of force per unit area.
c = The distance from the neutral axis
to the extreme fiber.

Description
OD
(in)
Wall
Thickness
(in)
E
GPA
S
y
MPA

g/in
3

Price/feet Miscellaneous Rating
AISI 1080 1 .120 200 400 0.28359 3.50
Easy to buy,
standard sizes, easy
to machine
7
AISI 1020 1 .120 200 380 0.28359 3.46
Easy to buy,
standard sizes, easy
to machine
7.5
AISI 4130 1 .065 205 670 0.28359 3.99
Easy to buy,
standard sizes, easy
to machine
8
Table 4

Since chrome moly is very common on the industry of chassis design because of its
mechanical properties such as high ultimate yield strength @ 670 MPA and because of its
hardness @ 197 on the Brinell scale when compared to the other carbon mild steels such AISI
1018 and AISI 1020, it is the selection that will be chosen for the manufacturing of the roll cage
assembly. Even though the price of the material is more expensive than the other mild steels, it
was highly recommended when consulted to race car drivers; it is a very good shock resistant
material and is really good for welding purposes due to a thinner wall thickness when compared
to the other two steels.
The frame will be welded using TIG (Tungsten Inert Gas) welding equipment and will be
using 4130 filler rods with
3
/
16
. This type of welding was chosen because it allows for deeper
penetration on the metal when doing this type of geometry, also the welding process is clean and
20
allows for detailed precision where most needed, namely on the joints for the front bracing and
the rear roll hoop. This type of welding is allowing for stronger, higher quality welds. However,
TIG is comparatively more complex and difficult to master, and furthermore, it is significantly
slower than most other welding techniques.

Frame alternate designs:
2006 Mini Baja team:

Figure 5
This concept was the one that was used for the 2006 Spring FIU Mini Baja team, it was
analyzed and used as a staring point, and most of the base lines were used from the overall
length, width and height. Since the model was already constructed and it was tested, an
investigation was performed to find ways to shorten the car and to find out ways to correct the
dynamics of the car. Some of the problems that were reported from the previous team were the
following:
1. Car weighted more than 700 lbs
21
2. Overall length more than 105 in (Max .SAE recommended)
3. Small W/L ratio
4. Narrow turning radius
5. 73 in tall
With these basic concepts the other three models were constructed.
First draft for spring 2007 FIU Mini Baja team:

Figure 6

The rules and regulations were carefully reviewed in order to understand the scope of the
roll cage, then an initial draft was drawn in order to capture all of the requirements prescribed by
the competition while at the same time the problems that were reported from lasts years team
were addressed. Some of the problems that were found with this model were the following:
1. Overall length anticipated to be more than 105 in
2. Non functional tapered bottom member
3. Difficult manufacturability
22
4. Rear roll hoop (Firewall) bent too high, wasted space that could be utilized for the
flotation system
With an initial draft the model was constructed out of PVC in order to have real time
representation of the model, the prototype reaffirmed the problems mentioned above.

Second draft for spring 2007 FIU Mini Baja team:

Figure 7


With a prototype already built, changes were starting to take place in order to address all
of the issues that the team has been discovering in regards to manufacturability and vehicle
dynamics. The second draft came directly from chopping off and creating different ways to do
the same, yet in a different manner. With this model already made, the final draft was modeled,
and then manufacturing of the frame will take place.

23
Final draft for spring 2007 FIU Mini Baja team:

Figure 8
This model has many advantages as described below:
1. Shorter in length and height while making it wider for better stability
2. Designed for manufacturability
3. Limited number of welds makes manufacturing easier and faster
4. Structural integrity kept to the highest degree by keeping shorter and uncut
members by creating bents or reinforcing bracing.
24
Actual frame design for spring 2007 FIU Mini Baja team:

Figure 9

Figure 10
25


Figure 11
Figure 11 and 12 depict the configuration for the drive train, the tubing is
made in such as way that the welding will be minimized while keeping the
integrity of the tubing intact by avoiding unnecessary cutting.


Rear Suspension
In analyzing the possible design applications for the Mini-Baja there are many
possibilities which can be chosen in order to ensure the Mini-Baja will be able to perform
adequately off-road. The possible choices allowable for this design include a solid rear axle with
leaf-spring or coil springs, or an independent rear suspension with the possible choices
mentioned above. Each of these suspension types have there advantages and disadvantages
which ultimately influenced the group on the final design.
The solid rear axle has the advantage that the power can be easily transferred from the
engine to the rear tires evenly and efficiently through a clutch placed at the center of the rear
tires. The suspension advantage is that it allows for an easy set up with having much problem.
The disadvantage to this design is that with a solid rear axle reduces the allowed clearance
26
between the debris and the bottom of the Mini-Baja because the axle rides lower than the actual
frame itself and at a complete horizontal.
Having an independent rear suspension compensates for the disadvantage of the solid rear
axle by raising the contact point of the trailing arms the ground clearance becomes
approximately similar to that of the bottom of the Mini-Baja. Having a leaf-spring suspension
although effective would add more weight to the overall design which is counter productive to
the goal of the design of a light and durable frame. The coil springs disadvantage is that remains
somewhat exposed to the debris unless it is placed behind the frame to protect it from the
oncoming debris.

Figure 12
The minimum desired suspension travel is 10 inches to allow for a wide range of travel
under many different circumstances. With the trailing arms angled outwards on the frame this
also allows for greater stability while reducing the rollover.
When designing the trailing arm suspension the resulting moment effects have to be
calculated to make sure that the dimensions of the cross-section in the trailing arms in order to
ensure that the supporting arms are not going to experience plastic deformation in a range of
foreseeable events that may occur. The coil spring and damper calculations are applied in order
to measure a static displacement when the Mini-Baja is not moving and to ensure a ride that is as
smooth as possible when driving on the rough terrain.

27
Flotation
One of the many tests in the Mini Baja competition is to traverse a large body of water, such as a
lake. The Mini Baja car must be designed to include a flotation device that will aid its
expedition. The competition requires that the largest driver be in the car at the time of the test
and that the vehicle may demonstrate a range of static roll stability of at least 30 degrees.

Figure 13

In order for the car to float, extensive research was done on buoyancy forces. The Archimedes
principle is considered when calculating the amount and allocation of the flotation device. It
states that any body partially or completely submerged in a fluid is buoyed up by a force equal to
the weight of the fluid displaced by the body. Density is used to relate the weight and the
displacement since it is defined as weight per volume. If the density of the object is less than the
density of water, then it will float on the surface on the water, and the object is considered to
have positive buoyancy. If the density of the object exceeds the density of water, it will sink,
and the object is considered to have negative buoyancy.

The buoyant force of an object is:
Vg Fbuoyant =
where is the density of the water, V is the volume of the object submerged, and g is gravity,
which is equal to 9.81 m/s
2
on earth.

The design of the flotation will greatly depend on the weight of the car (including the weight of
the heaviest driver) and the material used. The flotation will be made of foam. The foam will be
28
then coated will a material that is capable of maintaining the foams shape. Some examples of
flotation designs are shown below.

Figure 14

Figure 15
Another aspect of the flotation device that is important is the allocation of the material
throughout the car. The center of gravity is the point where all of the mass is considered
concentrated. It is important because the material needs to be placed in a way so that the car is
balanced at all ends. Like a boat, our car will lift slightly in the front because our motor is
located in the back.

Figure 16
29
A front bumper, as shown in the image above, will be used to aid the cars travel through the
water.

Transmission

The transmission chosen to drive our vehicle is a continuously variable transmission
(CVT). This transmission operates by changing the ratio of the rotational speeds of the shafts
driving it, thus allowing a variance and an infinite number of possible gear ratios. The CVT
works within a finite operating range, but within that range there is an infinite number of gear
ratios, therefore allowing the vehicle to be driven at high speeds or at high torque, depending on
the application of the vehicle. This transmission choice allows the engine to run efficiently at
any speed within the given range.

As with any mechanical element, there are many advantages and many disadvantages to this
transmission, as compared to other transmissions, specifically hydraulic automatic transmissions.
The advantages are as follows:
Variable vehicle speeds, allowing peak engine efficiency, resulting in improved fuel
economy and exhaust emissions;
Prevent torque converter losses; and,
A smooth, non-jerking operation.

The only major disadvantage of using a CVT is that it is limited in its torque handling
capability. The torque produced is restricted by the strength of the belt or chain used, and their
ability to withstand friction wear between the source of torque and the medium used in the
transmission box. This then limits the application of suck transmissions to low powered vehicles
and other light duty applications.

For our purposes, a CVT employs all the necessary elements to successfully operate our
vehicle. The transmission we will use on our Mini Baja vehicle has a custom built 9:1 gear ratio.
In combination with the CVT, at low speeds with a ratio of 3.34:1 will allow for increased torque
and thus faster car acceleration; and, at higher speeds with a ratio of 8:1 will allow for increased
30
speed therefore maximizing the top speed of the vehicle. This CVT will permit us to compete in
every part of the Mini Baja competition, and to contend at maximum effectiveness.

Build Phase

Team Meetings and Progress

December 13, 2006
Nick and Richard met with Stephanie Strange and Avy Weberman to discuss potential
sponsorship opportunities. The meeting was to reevaluate our proposal with Avy and to
determine what corporations could be used as sponsors for the 2007 Mini Baja competition.

December 28, 2006
During the team meeting, in the Student Machine shop, a workshop was conducted in
order to determine the skills of each member for the overall fabrication process. The skills tested
during this workshop involved taking accurate measurements, notching, and cutting.

Figure 17
31
In this workshop the members had to measure certain peaces at the given specifications in
order to accurately determine the skills of the members based on dimensional accuracy of the
desired final product. At the end of the workshop it was determined that Ricardo, Jorge and Avi
were determined as the ones in charge of the cutting and notching processes.


January 6, 2007
The team held another workshop to determine the members that would be in charge of
the welding process of fabrication. In order to conduct the workshop properly without damaging
the equipment an experienced welder, Francisco Rodriguez, to teach the members the
fundamentals of welding to the members and so he could accurately judge the welds by the given
members. At the end of the day, it was determined that Nick and Richard are going to be in
charge of welding.

Figure 18
January 10, 2007
The group met to distribute the tasks of the Mini Baja vehicle design. The tasks were
divided as follows:
Elena and Ricardo Flotation
Avi Rear Suspension
32
Richard Transmission and Motor Design
Jorge Frame Design and Front Suspension
Nick Brake System
January 12, 2007
Materials for the prototype were purchased:
100 feet of 1 outer diameter PVC
Duct Tape
PVC Glue
January 13, 2007
The team members in charge of the fabrication processes met in order to fabricate the
frame that was our first design from the previous semester which was modeled by Jorge. To
improve manufacturability modifications to the frame were required.

January 14, 2007
Richard, Ricardo and Avi came to the Student Machine Shop to redesign the previous
frame. It was found that a box bottom to the frame would be easier for fabrication and
proportionally provided for good base dimension in space conservation in the cockpit.

January 16, 2007
Nick and Avi met in the Student Machine Shop in order to determine if the modeled
frame was able to meet the desired regulations set forth by the Society of Automotive Engineers.
Height: The roll cage must be six inches above the tallest drivers head with the helmet
Shoulder width: 3 of clearance from the drivers shoulder to the vertical roll bar bracing
Drivers comfort
This concluded that additional modifications could be made to the frame to reduce the
overall length and improve the vehicle dynamics.

January 17, 2007
Richard, Ricardo and Avi went the Student Machine Shop to complete the prototype.
The overall height and length of the prototype was able to be reduced 5 vertical and 4 in
length.
33


Figure 19

January 18, 2007
Nick Gimbel: Internet Brake Research
http://zjtongshun.en.alibaba.com/product/50228279/51224371/Motorcycle_Parts/ATV_Brake_A
ssembly.html
Possible brake design
Brake assembly parameters:
1) Max. operation pressure: 8MPa
2) Master cylinder diameter (hand brake): 12.7mm
3) Master cylinder diameter (foot brake): 19mm
4) Mounting position of caliper (F/L): left/right
5) Mounting position of caliper (R): right
6) Length of oil pipe (F/L): 1,850mm
7) Length of oil pipe (R): 600mm
8) Length of oil pipe (foot brake): 880mm
9) Length of oil pipe (foot brake R): 1,500mm
Brake disc parameters:
1) Rear disc:
34
a) O.D.: 190mm
b) I.D: 91mm
2) Front disc:
a) O.D.: 190mm
b) I.D.: 58mm
January 19, 2007
Ricardo and Jorge completed the Solid Works drawings of the new, updated, redesigned
prototype.
January 22, 2007
Nick Gimbel: Sponsorship seeking and visiting potential sponsors, sent an email with
the proposal attached to various potential sponsors in the South Florida area and visited with one
sponsor to discuss proposal, CH Perez & Associates.

February 2, 2007
Jorge, Ricardo and Avi traveled to Engineering Chassis in order to pick up the stock and
bent tubing for the rear roll hoop and to begin the fabrication of the frame.

Figure 20
February 3, 2007
Jorge, Ricardo, Nick and Avi completed the rear roll hoop (with exception to inner
welds), along with the welds joining the bottom support of the frame to the rear roll hoop.
35

Figure 21

February 8, 2007
Avi picked up tubing from Chassis Engineering. Tubes were bent to specified radii.
Supplies were left in the shop.
February 10, 2007
Jorge, Avi, Richard, Ricardo completed the bottom chassis with supports (not welded, cut
to size and notched). Cut the supports to the Rear Roll Hoop and cut the Side Impact Members.

Figure 22
36
February 11, 2007
Jorge, Avi, Richard, Ricardo, and Nick completed the bottom chassis including welded
bracing. Rear Roll Hoop bracing welded on. Side Impact member notched.


Figure 23
February 15, 2007
Avi met with Professor Zicarelli in order to obtain advice in the manufacturing of the
frame, to which he then purchased a cobalt-roughing-end-mill in order to complete the
fabrication process in a timely fashion.

Figure 24
37
February 16-17, 2007
Richard, Ricardo and Avi completed the bracing for side impact member along with the
horizontal bracing of the front bracket on the frame.

Figure 25

Figure 26
February 19, 2007
Ricardo ordered the components for the front suspension and drive-train.
38
February 20, 2007
Ricardo placed placed an order for the following components:
Helmet: FX-85 Blue Medium
Goggles: Answer Racing Blue
Front Rims: Douglas .125 Blue Label 10x5
Front Tires: Maxxis iRAZR 22x7-10
Rear Rims: Douglas .125 Blue Label 8x8
Rear Tires: Maxxis Sur Trak 22x11-8
February 23, 2007
Ricardo and Elena presented at the Engineering Gala for the middle and elementary
school students.
February 27, 2007
Richard brought the Briggs and Stratton 10 HP engine to the shop.

Figure 27
March 1, 2007
Ricardo brought the front dampers and springs to the shop. Avi cut out the blank from
the aluminum sheet metal that covers the gap between the side impact member and the bottom of
the frame.
39

Figure 28

Figure 29
40
March 2, 2007
Avi cut out the blank from the aluminum sheet metal for the rear roll hoop and bottom of
the frame.

Figure 30


Figure 31
March 3, 2007
The team modeled Briggs and Stratton 10 HP Engine in Solid Works.
March 5, 2007
Nick and Jorge began modeled the CV joints and steering components in Solid Works.

March 6, 2007
Jorge and Nick modeled the front dampers in Solid Works. Avi cut out tabs from 1/8
chrome moly as tabs for the aluminum sides.
41

Figure 32

March 8, 2007
Elena was able to find sponsors for the remaining money necessary to complete the
project. Ricardo received the transmission and brought it to the student machine shop and along
with the rest of the team began modeling the rear roll hoop that will allow for foam positioning,
clearance with trailing arms and rigidity.

Figure 33
March 02 08 12, 2007
Most of the components that were purchased thought EMPI and Team Mot were received
and were allocated in the student machine shop and almost all of the remaining components that
were on order with the exception to the CV Driver side and the stub axles.
42

Figure 34


Figure 35
March 10, 2007
The team modeled many of the remaining components in solid works.
March 11, 2007
Richard brought the rear dampers and springs to the shop from last years car, the coil
over on the springs will be decompressed to avoid an over damped rear suspension.
March 12, 2007
Richard brought a set of rear suspension springs as spares and also to try different
configurations on the car to make sure that we can optimize the configurations and set ups of the
components in the car. Since most of the components are in house the assembly of the parts will
be taking place during the next two weeks to finalize the functional part of the car, the next steps
are to finalize the configuration and construction of the flotation device.
43

Figure 36

Figure 37
44
Components fully assembled as of March 13, 2007:

Front suspension
o Front Shocks
o Front A Arms
o Hubs, Spindles, Brake calipers, brake rotors
o Tires and rims
Transmission
o CV joints
o CV shafts
o Trailing Arms
Components fully assembled as of March 25, 2007:

Steering
o Rack and pinion
o Steering shaft and U-joints
o Connecting rods and misalignment spacers
o Steering wheel and quick release
o Steering support
o Rack and pinion support
Brakes
o Brake pedal
o Front and rear brake lines
o Brake pedal support
Sheet metal
o Front panels
o Side panels
o Firewall
o Bottom panel
Rear suspension
o Rear trailing arms assembled and mounted
45
o Brake pedal support

Components fully assembled as of April 11, 2007:

Flotation
o Remaining components fabricated
o Supporting brackets
o Front flotation mounted
o Bottom and side flotation mounted
o Rear dove tail flotation mounted
o Trailing arms flotation mounted
Drive train
o Morse cables (Transmission and engine)
o CVT belt mounted and aligned
o Engine mount welded and braced
o Transmission mounted and tranny mounts welded
46
Testing

Suspension:

Camber: The camber of the front suspension was tested by means of locking the steering
in one direction and then verifying that the suspension response was both adequate as well as
responsive. Then the car was verified on a static position and a driver fully strapped into the car
with all of the gear and all of the components of the car fully assembled, the purpose of this test
was to make sure that on a static position the front tires are perfectly perpendicular to the ground;
making the suspension pivot at a perfect plane providing the full range of motion on the
suspension. The car was then test driven in order to make sure that the tread wear was evenly
distributed on both front tires, the car was used on concrete so that
Suspension travel: The suspension travel will be determined by means of maximum
deflection of the control arms and appropriate spring adjustments to make sure that the spring
return is appropriate.
Damping: The damping of the front and rear shock absorbers needed to be

47
Drive train:

Engine tuning (governor plate)
Morse cables adjustments
Collision verification
Transmission Engine alignment
Top Speed

48
Steering:

Connecting rods: During the initial stages of the testing phase, this was one of the
components that required the most attention due to the fragility and high impact location in
which it was located. Initially the rods where made out of mild steel 1018 with an outside
diameter of
3
/
8
extending from the clevis to the female ball joint, during the first testing
sessions, the rods had bent and they were already jeopardizing the steering system by showing
signs of striped treats and potential cracking at the welded portions of the rods. The system was
strengthen by increasing the diameter of the shaft to 1 and using bigger female ball joints of
20 providing more contact surface as well as better resistance to bending due to the oversized
shaft; as a result the steering became very responsive.
Ball joints: The original ball joints that were purchased for the car where for 5/16 bolts,
and for inside diameter for the misalignment spacers, since the shaft was oversized a
combination of bigger inside diameter for the misalignment spacers and treated bolt was
required, thus the ball joint used is a grade 8 20 threat pattern with an inside diameter of
3/8 for the misalignment spacers and the spindle connector. Adding extra support, rigidity to the
system and making the steering very solid.
Steering responsiveness: Using bigger components provided better rigidity on the
system, but it also allowed for weaker components to be exposed to the full range of forces that
the steering was being damaged by, as a result the supporting brackets that were holding the rack
and pinion were sheared off from the tubing, in order to compensate for the damaged bracing a
double layer bracing was applied in a manner that it will have compressive forces holding it in
place at all times; as a result stronger support aiding to the steering responsiveness.

49
Structural Integrity:

Cracks Fractures: After several rounds of testing for different types of failure modes,
the car was disassembled completely for inspection of weld penetration and weld integrity;
mainly at those locations that will be supporting the wheels, shocks, and engine compartment.
The car was tested under extreme conditions, top speeds in order to create as much vibration as
possible on drive train components to analyze their behavior, ramping off hills and roll over. It
was found that the car had several portions which required additional supporting due to the
design of the rear roll hoop and the engine supports design, it was discovered that during testing
that portion of the frame had cracks created by the bending moment of the car when landing due
to high impact drops when ramped off hills. It was also discovered that the engine support plate
was undertaking excessive unsupported vibrations and it was causing the welds to crack, it was
then addressed by supporting the bottom portion with angle plates. All other cracks were
addressed by adding supports on the bottom section so that the force will be dissipated amongst
many components that are redundantly supported rather than single points of contact.

Roll over testing: This test was inadvertently performed but was of great help in order to
confirm the limitations and strength of the components of the car and the integrity of the frame.
This test was performed by rolling the car 180
o
while doing high speeds, this allowed for the
frame to stop the car at impact while using only a single point of contact and being able to
withstand high levels of forces and bending moments, no damage was noted on the car, the frame
withstood the impact without bending, cracking or compromising the safety of the driver;
ultimately conforming to the design intent of the car. The frame has proven to be extremely
strong for collisions while doing top speeds, it has also proven that the safety features that the
frame was built upon had rewarded the safety of the design and last but not least it is a durable
long lasting frame that will provide enough support to undertake the rough terrain and conditions
of the competition.

Additional supporting: During inspection of the frame integrity it was discovered that
the rear roll hoop supporting all of the drive train components required additional supporting in
order to absorb the bending moment that was being created by the twisting motion that was
50
caused by high impact landing on less that all four wheels touching the ground at once. This was
achieved by adding bracing that will aid dissipate the impact force to those components that were
connected to the major components of the frame, namely the fire wall of the car which its design
makes it very rigid and structural compact. Additional bracing was added to the front suspension
extension bars in which they are single supported by the bottom piece of the frame, two
additional bars were connected in order to absorb some of the force magnitude caused by
jumping and hard landings; also for head on collisions that the car may encounter.

Braking:

Full lock up of wheels: Adjusting of brake pedal to provide proper ratio of braking
force; 60% front, 40% rear, talk about the difference of having used a 2 piston caliper vs a
regular ATV single piston caliper. Problems encountered at time of competition and other teams
configurations.
Brake adjustments: Purging of lines, pressure tests, full lock up force required on the
pedal, also the fact that we used a custom made rotor, the surfaces burned the original pads due
to the nature of the rough surface until it was removed.etc

51
Flotation:

Preliminary testing: Talk about the testing performed with the tires and a sample of the
foam to be used on the car and compared to calculated results.
Final testing: Final results of the flotation on a lake and race.





52
Appendix A: Sponsorship Proposal

Dear Sir or Madam:
It is my great pleasure to present to you the Florida International University 2006-2007
Mini Baja Competition Team.
This year GPR will be traveling to Ocala, Florida to compete at the Society of
Automotive Engineers (SAE) East competition against other colleges and universities across
North America. The objective of the Mini Baja competition is to provide college and university
students with a challenging project that involves the planning and manufacturing tasks found
when introducing a new product to the consumer industrial market. Students must function as a
team to not only design, build, test, promote, and race a vehicle within the limits of the rules, but
also to generate financial support for their project and manage their educational priorities.
In order for us to build the Mini Baja we need your financial support. GPR plans to raise
$12,500 to build and compete at this years SAE East competition. We have chosen your
organization to sponsor us because you are well respected in the community as well as in our
school. We want you to have the opportunity to associate yourselves with FIU Mini Baja Team.
Becoming a sponsor will give your organization:
Recognition in the support of higher education learning
Media coverage in local televised news and newspapers
National coverage through SAE
Tax deductible donations
Logo of the company displayed on the race car
We would appreciate if you could take the time to read our sponsorship proposal, and
seriously consider supporting the FIU Mini Baja Team. We invite you to ask us questions and
look us up on our website http://www.myspace.com/minibajafiu, for updates on the build,
sponsors and plans.

Kindest Regards,
GPR
Golden Panther Racing

53
Introduction

The Program Founded in 1905, the Society of Automotive Engineers (SAE) initiated a
dedication to enhancing the development of self-propelled machinery. Focusing on advancing
mobility in land, sea, air, and space, SAE takes an active role in the development of international
standards and in the making of cutting edge technology. Part of this commitment to the future of
the industry includes a large responsibility to ensure the next generation of engineers. Therefore,
SAE organizes student chapters at international universities and hosts the largest annual
collegiate engineering competitions in the world.

The Challenge

Mini Baja Series Competition

The SAE Mini Baja competition includes over 120 teams from various universities who
design, build, and compete in Mini-Baja style off-road vehicles that must survive rough terrain
and water. This competition focuses on the chassis and suspension design of the car, restricting
the motor to a standard ten horsepower Briggs and Stratton. Students are challenged to design a
rugged and reliable off-road capable car, while still keeping cost and maintenance affordable for
the theoretical consumer. Competition is focused on the design and innovation of cost effective
parts, as well as dynamic events that test the real world function of these vehicles. The cars must
follow strict safety and cost regulations, making the design of these cars challenging for student
engineers. These restrictions also make the events very competitive.


54
Student Benefits

The main goal of the Mini Baja competition is to provide engineering students an
opportunity to go beyond the textbook with real life design projects. From this competition,
students gain valuable experience in managing, machining, designing, and fabricating an actual
product. Students develop, engineer, and manufacture nearly every part of the vehicle. This
helps the students to learn how every decision affects the manufacturing and design process. The
project requires a significant amount of team work and cooperation in developing the Mini Baja
vehicle. Students are responsible for managing funds and running the team, which provides
them with valuable experience in business administration and management. The end result is the
opportunity to work on a dedicated team of future engineers and the sense of accomplishment
from completing this challenge.


55
Budget:
Mini Baja Competition Estimated Budget
Car Design & System
Frame Material $500.00
Driver Seat $250.00
Tires $700.00
Engine Donated
Transmission $1,000.00
Suspension $1,000.00
Brake System Kit $800.00
CVT $600.00
Transponder $300.00
Processing Materials $500.00
Controls $500.00
Total $6,150.00

Accessories
Radio Kit $70.00
Goggles $50.00
Gloves $40.00
Helmet $200.00
Frame Wrapping Material $200.00
Fire Extinguisher $50.00
Flotation Device $50.00
Total $660.00

Trip Expenditures & Other Fees (6 Members)
Registration Fee $500.00
Car Rental $100.00
Hotel $500.00
Per Diem $900.00
Total $2,000.00

Flotation $1,000.00
Subtotal $9,810.00
25% Contingency $2,452.50
Grand Total $12,262.50
Sponsorship Request Amount: $12,500.00

56
Actual detail of cost:

Description Category Total in Dollars Qty
Home depot miscellaneous tooling $67.10 1
Harbor Freigh tools tooling $41.66 1
Sears toolbox $25.00 1
Big lots paint $11.39 1
Home depot miscellaneous sheet metal $72.00 1
MotoSport wheels $29.99 2
MotoSport tires $65.99 2
MotoSport wheels $36.99 2
Motorcycle-Superstore tires $81.99 2
Motorcycle-Superstore goggles $14.99 1
Motorcycle-Superstore helmet $44.99 1
Moto Performance Products Inc Stub axle $79.95 2
Moto Performance Products Inc shipping $15.00 1
Ebay Front A-Arms $49.99 1
Ebay shipping $30.00 1
Ebay Front Hubs $96.49 1
SAE Registration $500.00 1
Ebay shipping $14.00 1
Ebay Front Shocks $232.50 1
Miscellaneous Trip Expenditures $1,000.00 1
Ebay shipping $20.00 1
Welding equipment welding equip $70.00 1
Drill bid and arbor notching equip $110.00 1
Moto-performance product inc drive train $2,830.66 1
Moto-performance product inc wire transfer $25.00 1
Transmission Detail 1
15 5/8 in AXLES,28 SPLINED,PR Detail 1
930 Boot Kit, CV JOINT KIT, NEW (VW-201) Detail 4
DRIVE FLANGE,002 TO 930,PR Detail 1
CHROME HD 36MM AXLE NUT,EA Detail 2
AXLE SPACER SET (6), IRS Detail z
IRS OUTER AXLE REAR WHEEL BEARING, EACH Detail 2
IRS INNER AXLE REAR WHEEL BEARING, EACH Detail 2
CENTER HUB,RR BRK DRUM Detail 2
HD 4 WHL BRK SGL LOW SQR RES Detail 1
EMPI BILLET THROTTLE PEDAL ASSMY Detail 1
MORSE CABLE, 8 FOOT Detail 1
3/16" Ball End Detail 2
Hook Clamps Detail 2
QUICK RELEASE 4 POINT BELT W/ TWIN HARNESS EA Detail 1
BRAIDED HOSE, EACH Detail 2
Steering Quick Disconnect Detail 1
U-Joint Detail 2
57
14" Rack & Pinion Detail 1
Splined Stub Adapter Detail 3
STEERING SHAFT BEARING 7/8 in Detail 2
500 Series Drive Clutch 1" Bore Detail 1
500 Series Driven Clutch 1" Bore Detail 1
Rear Wheel Bearing Housing Detail 2
Rear Wheel Bearing Caps Detail 2
Wheel Studs 14-1.5 to 1/2-10 Detail 4
BOLT 3/8-24X2.38 in 12PT(6) Detail 4
REAR AXLE SEAL KIT Detail 4
TIE ROD KIT FOR 3147 Detail 1
FOAM S/WHL,11 3/4 in,3 3/4DISH Detail 1
EMPI 930 CV JOINT, EACH Detail 4
Trailing Arms Detail 2
Shipping/ Tracking#: Detail N/A
Chassis engineering Chassis $304.74 1
Chassis engineering Chassis $126.12 1
Summit Racing tooling $259.90 1
Chassis Shop Frame Tabs $103.00 1
Chassis Shop shipping $61.30 1
Ebay Front A-Arms $100.00 1
Ebay shipping $20.00 1
Ebay Brakes front $5.00 1
Ebay shipping $12.00 1

Sponsors up to date
Boston Scientific, associate dean's office, Mechanical Engineering Department, FIU Foundation and
SGA is Pending Final Approval
Total grants to date $5,500.00
Grand total of spent money $6,557.74
Total money reimbursed $5,500.00
Future expenses $1,057.74



58
Florida International University
Donations
Please provide the requested information and forward your tax deductible donation to the FIU at the
following address:
Mail to:
FIU Mini Baja
10555 W Flagler Street
Florida International University
Miami, FL 33174
Make checks payable to: Mini Baja Team (FIU Mini Baja team on the memo line)
Contact Name: ________________________________________________________________________
Contact Phone Number: ________________________________________________________________
E-mail Address: _______________________________________________________________________
Sponsorship Donation: __________________________________________________________________
Sponsor name as it should appear on advertisement: __________________________________________
_____________________________________________________________________________________
Brief company or individual profile: _______________________________________________________
____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
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Please also include a copy of your company logo if you wish it to be shown. Digital formats are preferred
and can be e-mailed to minibaja.fiu@gmail.com.
(Please keep a copy for your records.)