SubSystems

The Chassis team is responsible for the overall vehicle frame and structure. They ensure that the frame is lightweight but strong enough to handle the extreme loads encountered during off-road racing. This includes material selection, frame geometry, and compliance with SAE safety rules. They perform finite element analysis (FEA) to predict stresses and optimize tube placement, as well as crash and rollover protection.

They control the welding for the team as well as the final safety checks prior to completion of build. The chassis also serves as the foundation for mounting all other subsystems, so the team must work closely with suspension, drivetrain, controls, electrical, and body & ergo to ensure proper fit and function.

The Suspension team is responsible for designing and optimizing the vehicle's suspension to ensure stability and traction over rough terrain. Their main tasks include selecting the geometry we use, Double A-Arms and a trailing arm, determining spring and damper rates, and analyzing wheel travel and load distribution. Key challenges involve balancing strength, weight, and manufacturability while meeting competition rules.

Tools like SolidWorks and ANSYS are used for modeling, stress analysis, and kinematic simulations. The Suspension team collaborates with the Chassis team to define mounting points, the Controls subsystem to ensure proper geometry, and the Powertrain to ensure clearance and articulation.

Powertrain is responsible for taking the power from our Kohler CH440 engine and converting it into propulsion of the vehicle. This process includes the implementation of a custom designed reduction gearbox to increase the torque output to the wheels and a Gaged GX9 constantly variable transmission (CVT) to account for the fluctuating speeds our vehicles experiences while still operating at maximum efficiency within a very small footprint.

This subsystem also designs the vehicle to have 4X4 capabilities. To do this, a carbon fiber driveshaft connects the rear gearbox to the front of the vehicle where the power is sent out to the front wheels. All of the components undergo finite element analysis (FEA) to ensure all strength and safety parameters are met before they are manufactured.

The Controls Subsystem allows the driver to safely guide and stop the vehicle, making it one of the most important parts of the car. It includes the steering system, braking system, and wheel assemblies, which contain key components such as the hubs, knuckles, uprights, and rotors. These parts work together to ensure smooth steering, reliable braking, and stable vehicle performance throughout the race.

In an off-road competition setting, these systems face intense stress, so the Controls Subsystem focuses on designing and building them for both durability and efficiency. By combining strong, lightweight materials with careful engineering, the Controls Subsystem helps give our team a competitive edge while ensuring driver safety and vehicle reliability.

The Body and Ergonomics Subsystem responsibilities encompass both aesthetic and functional aspects of the vehicle. They ensure the car presents a visually appealing exterior, provides a comfortable driving experience, and features body panels that are puncture-resistant and capable of shielding internal components from dirt and debris. Driver safety is a paramount concern; their design incorporates essential protective elements such as a safety harness, seat belt, headrest, and firewall to safeguard occupants during operation.

To achieve these objectives, they utilize carbon fiber in the fabrication of critical components including the seat, hood, and body panels. Their manufacturing process employs a wet layup technique, using foam molds coated with gelcoat and StyroShield to ensure structural integrity and surface finish quality

The electrical subsystem is responsible for the wiring of the engine kill switches and the brake lights. Although those are the only things that are required for a Baja car, they like to take it a step further and implement a gadget cluster that displays various data, and electrify other components of the car if it is deemed more efficient. They also custom make any container or dashboard that holds their components in place. This subsystem constantly looks for innovation and new ways to improve the Baja experience.