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Show Your Junk: 2012 Edition

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Soccerdan7 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Soccerdan7 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-09 at 3:01pm
How tight is the 6" overhead clearance to the frame on your car? It may be the wide rollhoop and SIMS that are throwing me off, but that driver looks awfully tall for that frame.
Danny

Cornell

(fall'07 - spring'12)
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10 races, 7 top ten's, 2 overall wins
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Post Options Post Options   Thanks (0) Thanks(0)   Quote NJITCaptain Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-09 at 3:46pm
Thanks for the comments gentlemen. The lights were for aesthetics and night driving. For the competition we'll shave off all the weight we can, including removing the headlights.

Our 6" overhead clearance is tight, maybe a little too tight. We have a seat adjuster and can lower the seat if we need to. I'm actually one of the shortest members in our team, 5'6" so most likely we'll have to lower the seat.

So many things we overlooked. Glad we have this forums to get views from other teams.
Josen D. Llave
Norton Engineering Consultants
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http://josen.webs.com/saebaja.pdf
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T_Patn Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-13 at 5:25pm
Tyler Patten
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ErikHardy Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-13 at 6:25pm
Hot Damn thats some nice bodywork!!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jeiB Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-13 at 8:16pm
sh*t...i would buy that baja lol. Great work guys!
Jeremie B.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T_Patn Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-14 at 1:01am
thanks, our design dept did the body work and a lil guy by the name of foose painted it. can't wait till june to show it in action
Tyler Patten
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Post Options Post Options   Thanks (0) Thanks(0)   Quote CLReedy21 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-14 at 1:23am
I don't know that I would run around posting that in public.

A6.1 

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The vehicle and associated documentation must be conceived, designed and fabricated by the team members without direct involvement from the professional engineers, faculty or professionals in the off-road and racing communities."
-Chris Reedy
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"Quick with the hammer, slow with the brain."
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Purduebaja Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-14 at 7:49am

Some updates on our progress. Plan to be running next week.
New gorilla axles have so much more articulation. Are they worth the price and headaches? Can't really say.
New uprights, moved away from the high upper A-arm setup to more of a hybrid configuration. Upper steel part will get gussets and the steering arm is replaceable in case of a crash. Some of our drivers don't like to let go of the steering wheel and we have ended up with some pretty nasty steering damage.

Rear bearing carriers


All new welded aluminum drivetrain mount which will rest on vibration isolators.

Chassis with textured powdercoat.




New gearbox, our first year machining our own gears.





Gearbox final weight without fluid, just under 20 pounds.


The new drivetrain setup.




Edited by Purduebaja - 2012-Apr-14 at 7:52am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T_Patn Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-14 at 10:54am
he was only doing the paint Embarrassed everything else was student made/ fabricated
Tyler Patten
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Post Options Post Options   Thanks (0) Thanks(0)   Quote otto Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-14 at 2:25pm
Originally posted by Purduebaja Purduebaja wrote:


Some updates on our progress. Plan to be running next week.


cool,

It looks like your steering knuckle and large steel "extender" are cantilevering the welds by the mounting, I assume the gussets you are adding should help this?  (How heavy are these, out of curiosity? thats a decent amount of steel to have on there!)

Failures in the steering for us generally occur in the tie rod somewhere (rod end or more recently bonded inserts to some composite.... Ermm but I think we've resolved the bonding issues.

How much angle do those CV joints get?  That looks like a plunging joint, is it?


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Post Options Post Options   Thanks (0) Thanks(0)   Quote abenn Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-16 at 10:42pm
Who's ready to head down to Auburn? We'll see you all there!

Andy Benn
Northeastern University Baja SAE
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T_Patn Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-17 at 12:04am
nice, I can't wait to see how the handlebar steering goes
Tyler Patten
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Post Options Post Options   Thanks (0) Thanks(0)   Quote NJITCaptain Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-17 at 6:19am
Nice A.B.! Beautiful shot. Looks like we're ready to go. See you there!

Josen D. Llave
Norton Engineering Consultants
New Jersey Institute of Technology
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http://josen.webs.com/saebaja.pdf
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ErikHardy Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-17 at 7:35am
Originally posted by abenn abenn wrote:

Who's ready to head down to Auburn? We'll see you all there!

Never knew Baja could be so romantic Heart
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Post Options Post Options   Thanks (0) Thanks(0)   Quote RKS2108 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-18 at 9:56am
Michigan Tech's Progress.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote collinskl1 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-18 at 10:01am
How is it driving for long periods of time with your legs elevated like that? 
Kyle Collins
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Nexteer Automotive
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Post Options Post Options   Thanks (0) Thanks(0)   Quote enkob2110 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-18 at 10:55am

I hever noticed any problems with the elevated feet, we actually think this is the most comfortable car we have made in recent years. The driver in that middle picture is 6'8", so the average person fits better.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote collinskl1 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-18 at 11:58am
I was just curious, since I'd never driven anything like that.  It does look pretty comfortable.
Kyle Collins
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Nexteer Automotive
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... and the 8th simple machine: a bigger hammer.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jeiB Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-18 at 12:19pm
Nice brake pedal Wink. Modified Polaris master cylinders?

And it looks pretty light. Any weight numbers?


Edited by jeiB - 2012-Apr-18 at 12:21pm
Jeremie B.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote RKS2108 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-18 at 6:37pm

We are currently at 315lbs. But this does not include body panels, CVT cover, firewall, etc. We will probably come in around 380lbs. The master cylinders are slightly modified rear Polaris predator parts.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote VivaLaShay Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-18 at 7:16pm
Nice cup holder
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Post Options Post Options   Thanks (0) Thanks(0)   Quote S&Tminer baja Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-18 at 10:56pm
Could be wrong, but doesn't the SIM have to come to a point farther forward than the driver's toes? You guys are running a straight footbox.
-Carl Lacy

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Post Options Post Options   Thanks (0) Thanks(0)   Quote dillon_b12 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-Apr-27 at 10:18am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ErikHardy Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 3:42pm
First time with these gear thingies for us.ConfusedAnd you can see where I set the depth wrong on the ol 2 axis haha


Edited by ErikHardy - 2012-May-15 at 3:43pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote otto Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 5:59pm
Originally posted by ErikHardy ErikHardy wrote:

First time with these gear thingies for us.ConfusedAnd you can see where I set the depth wrong on the ol 2 axis haha


face widths dont match exactly?  Otherwise looks nice.  Is that 20 degree pressure angle or something custom?  Get the gears machined, or bought them from a catalog?

here's a photo i found recently taken shortly after we sprung sometime in january that I like:



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Post Options Post Options   Thanks (0) Thanks(0)   Quote Purduebaja Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 6:48pm
ErikHardy

Is that a DGL I see there? Its our first year making our own gears as well and it has definitely been an experience. You guys definitely have more weight savings on the gears than us, congrats. What alloy, pressure angle, and diametrical pitch did you use? Ive seen some teams get their gearboxes to 15 lbs without a DGL but curious to see how much yours weighs

Alloy: 8620 heat treated to 60 HRa
Pressure angle: 25 degree with stub tooth addendum modification
Diametrical Pitch: 12 for first reduction, 10 for second reduction
Face widths : 0.5" first reduction and 0.75" second reduction
Final Weight: 22 lbs due to a heavy as hell DGL
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Purduebaja Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 6:53pm
Originally posted by otto otto wrote:

How much angle do those CV joints get?  That looks like a plunging joint, is it? 

The gorilla axles will do a maximum of 42 degrees articulation, and both the inner and outer ends plunge. Gorilla recommends running them at no more than 38 degrees just to be safe.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Soccerdan7 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 6:54pm
You can be well under 15 lbs without a diff...
Danny

Cornell

(fall'07 - spring'12)
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Purduebaja Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 6:57pm
Wow, care to share any figures you've heard?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Soccerdan7 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 7:02pm
Without giving away too much, I can tell you we are under 10 lbs and I am sure a couple other teams are as well. It all depends on what CVT you run and how much reduction you want out of the box. Those are the biggest decisions, actually optimizing the components saves less weight but you won't be under 20 without it.
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Cornell

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Purduebaja Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 7:30pm
Gotcha, we are running the Gaged GX9 which to my understanding doesnt offer as much reduction compared to others but is significantly lighter. What CVT do you guys run or do you make your own?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Soccerdan7 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 7:35pm
This is our first year with the Gaged as well, however it is modified some for performance advantages as opposed to weight savings. It is a very nice and light setup out of the box and allowed us to drop weight in the gearbox as well this year compared to our previous cvtech and heavily customized setups since less reduction is needed for the same geared top speed.
Danny

Cornell

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Purduebaja Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 7:55pm
Gotcha, well I can guarantee ill be talking to you at competition. Anyone know if Gaged is going to the Wisconsin competition?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote T_Patn Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 8:38pm
I would guess they will be since they were in IL last year
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Purduebaja Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 8:46pm
Good deal, I love talking with bill about CVTs during the little downtime I typically have
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ErikHardy Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 10:33pm
Its a front cam-paw differential from a Honda Rubicon that I stole out of an older formula car laying around. Its 20 degree PA and I believe 14 & 10 pitch that were machined for us (we had a lot of help and great sponsors!!). Yes the pinions are bigger than the gears, they are suppose to be slightly wider to account for spacing misalignments but those pinions widths are exaggerated tremendously. The plan is to use those gear sets for possibly the next two years (we got 3 full sets machined) so its nice to have some leeway with future gearboxes. Never weighed all of it but its kind of heavy, inboard brakes as well, maybe 20+ pounds... but somehow it all works and is tremendously quiet. The best part, no expensive splinesBig smile
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Purduebaja Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-15 at 10:51pm
Gotcha, that looks exactly like the diff we use in our car. You can replace the insides with the detroit gearless locker ones if your so inclined. You basically end up with a locked diff than doesn't skip or pull around corners. Our team has had great success with it for the last 4 years, others haven't liked it. May be worth some experimentation for next year. How do you like the cam pawl diff? We haven't ever tried the original part to compare.

Interesting that you didn't use splines. We had a company based out of milwaukee broach the gears and I don't remember it being too expensive. Can't remember if we got a baja discount though.

Edited by Purduebaja - 2012-May-15 at 10:52pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ErikHardy Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-16 at 7:56am
Loooooooved the Diff!! We have always run a spool so didn't really know what to expect with the diff. I was worried about the one wheel peel in the mud but was pleasantly surprised. The shim thats currently in there now leaves the diff relatively open which was excellent in the corners! Even in the Washington mud, never felt like I was going to get stuck. Its nice to be able to push the dam thing around without skidding a tire
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Post Options Post Options   Thanks (0) Thanks(0)   Quote sandres913 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-16 at 9:02am
Originally posted by ErikHardy ErikHardy wrote:

First time with these gear thingies for us.ConfusedAnd you can see where I set the depth wrong on the ol 2 axis haha

Holy gear reduction Batman!
And Thumbs Up for the diff! I'm looking at doing the same thing on our drivetrain next year! It looks like...*squints* a 4 spline? Interesting choice, machined in-house? Not bashing it at all, I remember the trouble we used to have with splines
Case looks very nice! You should polish that sucker! MO' BLING! LOL
Shaun
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2011 - Peoria #30
2012 - Wisconsin #54
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jeiB Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-16 at 9:05am
Originally posted by sandres913 sandres913 wrote:

Originally posted by ErikHardy ErikHardy wrote:

First time with these gear thingies for us.ConfusedAnd you can see where I set the depth wrong on the ol 2 axis haha

Holy gear reduction Batman!
And Thumbs Up for the diff! I'm looking at doing the same thing on our drivetrain next year! It looks like...*squints* a 4 spline? Interesting choice, machined in-house? Not bashing it at all, I remember the trouble we used to have with splines
Case looks very nice! You should polish that sucker! MO' BLING! LOL


Looks like the middle shaft/gears are one piece no?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ErikHardy Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-16 at 9:19am
Originally posted by sandres913 sandres913 wrote:

 Case looks very nice! You should polish that sucker! MO' BLING! LOL
Funny you say that, almost all of the case was cut with a 3/4" roughing end mill, it looks scruffyLOL A lot of it was done manually so theres a ton of mistakes haha.
The middle gear bits are welded together..
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Post Options Post Options   Thanks (0) Thanks(0)   Quote sandres913 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-16 at 9:28am
Originally posted by ErikHardy ErikHardy wrote:

Originally posted by sandres913 sandres913 wrote:

 Case looks very nice! You should polish that sucker! MO' BLING! LOL
Funny you say that, almost all of the case was cut with a 3/4" roughing end mill, it looks scruffyLOL A lot of it was done manually so theres a ton of mistakes haha.
The middle gear bits are welded together..

Well I meant the packaging, ours has a bit of space to it this year and last year...actually come to think of it most of ours have been aluminum boxes due to price of aluminum and little funding

ShockedShockedShockedShockedShockedShockedShockedShockedShocked WELDED? Clap As in no keys or snap rings, just plain welded to the shaft? Gears hardened at all? Our welder (graduated now) generally denounces welding things together like this...even though his welds are legendary among a few judges.

EDIT: Guess that could sound like a dick comment...Not bashing the finish on the case, doesn't look bad, I was just focusing on the packaging is all! Thumbs Up


Edited by sandres913 - 2012-May-16 at 10:52am
Shaun
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ErikHardy Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-17 at 8:10am
No Keys, no snaprings, straight up welded carburized 8620. Unfortunately I think you have become victim to something that I think all us (myself included!) SAE students fall into at one point or another. We become so used to what is available to us in the shop that we start assuming, bad for engineering! In this case you are probably assuming they were tig welded, which is possible and would probably work but would cause a myriad of other problems. There is a welding process perfect for this application. I'll give you a hint, you can almost grab the part after being welded due to heat input...Smile
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Post Options Post Options   Thanks (0) Thanks(0)   Quote VivaLaShay Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-17 at 8:14am
Originally posted by sandres913 sandres913 wrote:

Originally posted by ErikHardy ErikHardy wrote:

First time with these gear thingies for us.ConfusedAnd you can see where I set the depth wrong on the ol 2 axis haha

Holy gear reduction Batman!
And Thumbs Up for the diff! I'm looking at doing the same thing on our drivetrain next year! It looks like...*squints* a 4 spline? Interesting choice, machined in-house? Not bashing it at all, I remember the trouble we used to have with splines
Case looks very nice! You should polish that sucker! MO' BLING! LOL

Thats a Honda diff

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Post Options Post Options   Thanks (0) Thanks(0)   Quote J.Cremer Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-17 at 8:19am
[QUOTE=ErikHardy]No Keys, no snaprings, straight up welded carburized 8620.... 


Just wanted to add a correction, the weld was not on the carburized material.  Thats a no-no.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote sandres913 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-17 at 1:00pm
Originally posted by VivaLaShay VivaLaShay wrote:

Originally posted by sandres913 sandres913 wrote:

Originally posted by ErikHardy ErikHardy wrote:

First time with these gear thingies for us.ConfusedAnd you can see where I set the depth wrong on the ol 2 axis haha

Holy gear reduction Batman!
And Thumbs Up for the diff! I'm looking at doing the same thing on our drivetrain next year! It looks like...*squints* a 4 spline? Interesting choice, machined in-house? Not bashing it at all, I remember the trouble we used to have with splines
Case looks very nice! You should polish that sucker! MO' BLING! LOL

Thats a Honda diff


Just standard Honda? Only really seen Polaris and Arctic Cat

Originally posted by ErikHardy ErikHardy wrote:

No Keys, no snaprings, straight up welded carburized 8620. Unfortunately I think you have become victim to something that I think all us (myself included!) SAE students fall into at one point or another. We become so used to what is available to us in the shop that we start assuming, bad for engineering! In this case you are probably assuming they were tig welded, which is possible and would probably work but would cause a myriad of other problems. There is a welding processperfect for this application. I'll give you a hint, you can almost grab the part after being welded due to heat input...Smile

Yeah you're pretty much rightCry We've got Stick, Mig n Tig. So of course all we do is Tig mainly. Never actually seen Stick done first person. But if I had to guess.......Laser or Mig? Confused
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ErikHardy Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-17 at 1:14pm
Think outside of what is available to you at the moment in the shop. There are a ton of different welding processes, each of them have their advantages and disadvantages. I'm not going to tell you what we used, I'll let you do your own research Tongue
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Post Options Post Options   Thanks (0) Thanks(0)   Quote sandres913 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-17 at 1:17pm
Originally posted by ErikHardy ErikHardy wrote:

Think outside of what is available to you at the moment in the shop. There are a ton of different welding processes, each of them have their advantages and disadvantages. I'm not going to tell you what we used, I'll let you do your own research Tongue

Fair enough! In either case, it looks like a very clean and precise weld, very cool!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ErikHardy Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-17 at 1:23pm
The weld is on the other side haha
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Post Options Post Options   Thanks (0) Thanks(0)   Quote sandres913 Quote  Post ReplyReply Direct Link To This Post Posted: 2012-May-17 at 1:24pm
Originally posted by ErikHardy ErikHardy wrote:

The weld is on the other side haha

BAH! That would explain it! @_@
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