How to Build a BAJA ATV in 40 Steps
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Transcript of How to Build a BAJA ATV in 40 Steps
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HOW TO BUILD A GOOD BAJA ATV
(BUGGY) IN 40 STEPS
Team STRATOS
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1. SUCCESS AT BAJA= DEDICATED TEAM +
SMART CAPTAIN + HELPFUL FACULTY ADVISOR
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2. DIVIDE THE TEAM, RESEARCH, BRAINSTORM,
DISCUSS, DEBATE AND ARGUE
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3. MAKE A BASE PLAN AND THEN 3D CAD
WIREFRAME
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4. BUILD PROTOTYPE OF SPACE FRAME. ESP.
FOR FIRST TIMERS
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5. CAD MODELS AND ANALYSIS
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5A. PRELIMINARY AND FINAL MODELS
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6. OBTAIN A NICE AND TIDY WORKSHOP
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7. SET TABLE ACCURATELY AND MAKE
MARKINGS
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8. START FROM THE BASE WITH NECESSARY
MATERIALS
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9. FINALIZE AND SECURE BASE
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10. BUILD UPWARDS USING EFFECTIVE JIGS,
MAINTAINING ACCURACY ALL THE WHILE.
ALL CHANGES(IF ANY) MADE IN THE PHYSICAL MODEL MUST
BE REFLECTED IN THE CAD MODEL
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11. ACCURATE EDGE PROFILES ARE CRUCIAL
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12. SPOT TALENTED WELDER(S), ENCOURAGE
SUFFICIENT TRAINING AND START WELDING
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12A. GOOD WELDS ARE THE SECRET OF A GOOD
CAR
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13. SCHEDULE WELL THROUGHOUT
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14. KEEP SPONSORS IN THE LOOP
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15. ENSURE FIT OF CRITICAL COMPONENTS
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16. COMPLETE FRAME
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16A. NOW BRING THE FRAME TO THE DESIRED
RIDE HEIGHT. HELPS IN SUSPENSION BUILD
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17. WORK ON SUB-COMPONENTS MUST BE
ATLEAST HALF WAY THROUGH
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18. ALSO ARRANGE FOR ALL ACCESSORIES
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19. START THE ASSEMBLY!
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20. FINISH CRITICAL COMPONENTS FIRST:
A-FRONT SUSPENSION
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B-REAR SUSPENSION
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C-HUBS
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D-STEERING ASSEMBLY
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E- DRIVETRAIN
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F- BRAKE LINES, TIE RODS AND INNOVATIONS
(IF ANY)
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21. INSTALL THE OTHER ESSENTIALS: SEAT,
SAFETY KIT, ETC
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22. ELECTRICAL AND BODY PANELS ARE
OPTIONAL AT THIS STAGE
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23. TIME FOR THAT FIRST EVER TEST DRIVE!!
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24. DISCUSS IMPROVEMENTS NECESSARY
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25. STRIP DOWN ALL THE PARTS FOR PAINT
JOB. START BY SPRAYING RED OXIDE
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26. MAKE IMPROVEMENTS TO OTHER PARTS OF
THE CAR SEPARATELY.
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27. APPLY PRIMER ON THE FRAME
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28. MIX PAINT WITH THINNER APPROPRIATELY
AND TRY OUT
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29. NOW GIVE ATLEAST 2 COATS OF PAINT
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30. RE-ASSEMBLE THE CAR
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31. COMPLETE THE CAR TO THE MAXIMUM
EXTENT: BODY PANELS, INNOVATIONS, ETC
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- COCKPIT
DIGITAL FUEL
GAUGE - Hidden
multimeter with
custom fit LEDs!
DIGITAL GEAR
INDICATOR
N123 I-Pattern
Gear shift
Dual tone
dashboard Horn button
4 terminal (IG-
BI-15-ST)
Ignition switch
Lights
Speedometer
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32. RUN FIELD TESTS FOR ATLEAST A MONTH
(CRITICAL)
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33. MAKE YOUR COLLEGE COME TO LIFE AT 3AM
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34. HOPE THINGS FAIL HERE SO YOU CAN YOU
CAN BE SAFER ON RACE DAY
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35. TEST MORE AT TOUGHER PLACES.
Courtesy: Dirt Mania ATV dirt track, Kanakpura Road, Bengaluru
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36. HOPE MORE THINGS FAIL AT THE RIGHT
TIME
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37. REPAIR AND TEST EVEN MORE.
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38. GO BACK TO GARAGE. CLEAN UP, TOUCH UP
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39. SHIP TO RACE TRACK
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40. KEEP TOOLS AND SPARES HANDY AND
HOPE FOR THE BEST AT BAJA!!
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IF THINGS DON’T WORK OUT, DON’T BE TOO
DISHEARTENED..
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..YOU MIGHT STILL GET TO WIN ANOTHER DAY!
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MY PROFILE..
I had the wonderful opportunity to be the captain of the much acclaimed 'Car#8-BOSCH Team Stratos, BIT', the team representing the institution at the BAJA SAEINDIA 2010 Competition, held at NATRAX, near Indore, M.P. This was the first time such an attempt was made in our college and were the only ones from Bangalore.
Apart from being the skipper, I had a major role in the design phase of the all-terrain vehicle (ATV), using CATIA V5 extensively in part design, assembly, anthropometric analysis and use of in-built analysis package. I was involved in marketing as well, with the team getting major sponsorship backing from Bosch Ltd., among many other prominent companies. I’ve created the Team sponsorship brochures. Also have designed and implemented all the electrical systems in the car.
My team consisted of 20 brilliant 4th, 3rd and 2nd year mechanical students. Our car was used to inaugurate the event as our team had won laurels for having the Best Design Report.
We got our first podium finish at the BIAE ATV University Challenge when we finished at 2nd place in a 21Km endurance race.
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A FEW TIPS..
You are most likely to have one shot at BAJA. So, keep reliability of all aspects largely within spec.
Test, test and test more. Parts break when you least expect. This is that sort of terrain. I suggest atleast a month’s testing.
Never EVER underestimate your opponents.
Rule: OEM parts are ALWAYS more reliable than custom made ones.
Respect the track. Its professionally crafted to reduce your car to shreds. This is where your worst case scenario is your most likely scenario.
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MY BEST WISHES TO ALL FUTURE BAJA
ASPIRANTS!!
-Manish O.
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THANK YOU!
Do give suggestions and/or comments to make this more helpful.