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Maverick Motorsports 2005 Car# - Conceive, Design, Fabricate, and Compete in Formula-Style Car Competition

The purpose of this event is to manufacture a reliable, high-performance formula-style car within a low cost and easy to maintain design. The event includes various competition events such as technical inspection, cost and manufacturing analysis, presentation, design, acceleration, skid pad, autocross, fuel economy, and endurance. The team's goals for 2005 include creating a reliable car that will finish each FSAE event, improving performance and driver positioning, and establishing repeatable decision-making methods. The car features a Honda F4i 598cc 4-cylinder engine converted to run on E-85 ethanol, a single plenum intake design with a 19mm restrictor, a custom drivetrain with interchangeable drive and torque proportioning differential, a chassis with a removable rear box for easy engine servicing, and a reliable brake and steering system. The suspension includes custom machined uprights and hubs, double unequal length A-arms, and pushrod actuated spring/damper. The car is equipped with 13" x 6" Keizer spun aluminum rims and Goodyear slicks and rain tires. The team has also created a documentation binder for future teams to follow and has considered vehicle cost in their design.

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Maverick Motorsports 2005 Car# - Conceive, Design, Fabricate, and Compete in Formula-Style Car Competition

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  1. Maverick Motorsports 2005 Car# 28 Scott Rector Mike Schmitz Jamie Schlachter Ryan Schommer Ryan Stebbins Paul Steevens Mike Tichy Ben Gruenzner Nick Hanson Aaron Pilger Dustin Kalhoff Chris Kost Jason Kuenzli Justin Moe Faculty Advisors: Dr. Bruce Jones and Mr. Gary Mead

  2. Purpose of the Event • Conceive, design, fabricate, and compete a formula-style car • Low cost • Easy to maintain • Reliable • High performance • Knowledge and creativity is challenged because of chassis and engine restrictions • Gain experience in a meaningful engineering team project

  3. Competition Events Static Events Technical Inspection No points Cost and Manufacturing Analysis 100 points Presentation 75 points Design 150 points -------------------------------------------------------------------- Total 325 points Dynamic Events Acceleration 75 points Skid Pad 50 points Autocross 150 points Fuel Economy 50 points Endurance 350 points -------------------------------------------------------------------- Total 675 points

  4. 2005 MSU FSAE Goals • Manufacture a reliable car that will finish each FSAE event • Simple design • Easily manufactured and assembled • 425 lb weight • Increased performance acceleration, braking, and handling • Create a documentation binder for future teams to follow • Better engine package • Improved driver positioning • Repeatable decision methods

  5. Decision Matrix

  6. Engine • Honda F4i 598cc 4-cylinder engine • Naturally aspirated • Converted to run on E-85 ethanol • Performance Electronics Engine Management System

  7. Intake Design • Single Plenum Design • 19mm Restrictor • Heimholtz Calculations

  8. Exhaust Design • Only Scott Knows

  9. 3-31-05 FSAE Dyno run 3

  10. Drivetrain • 6 speed, cockpit shifted manual transmission • Interchangeable drive • Torque proportioning differential • Direct drive aluminum spool • Custom RCV drive axles • Drive sprocket and chain driven

  11. Chassis • MIG welded 1020 steel tubing and 1020 square tubing on the rear differential box • FEA Beam Structure Design • engine as a semi-stressed frame member • rear box removable for easy engine servicing • 11.4” vertical center of gravity • 48% Front / 52% Rear weight distribution • 50%-50% left-right balance

  12. Brake System • One dual piston caliper on each front wheel • One four piston caliper on the rear drive shaft • Two master cylinders: one to control the front brakes and one to control the rear brake

  13. Steering System • 12:1 Steering ratio • Less than 1/16” of Bump • 30° of total steering • 67% Ackerman Angle • Track width: 47” front and 45” rear

  14. Suspension • Custom machined uprights and hubs • Double, unequal length A-arms • Pushrod actuated spring/damper • 2.00” of total travel • SusProg3D software used to simplify component placement • 66” wheelbase • Minimal camber change • Low roll center • Rising Spring rate

  15. Upright Designs • Aluminum • FEA Design • FEA Picture

  16. Tires and Wheels • 13” x 6” Keizer spun aluminum rims are used • allows more room for packaging • chosen because of weight and cost • 20X6.5-13” Tires • Goodyear Slicks and Rain Tires

  17. Documentation • Design Report • Document Binder

  18. Vehicle Cost

  19. Any Questions?

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