BUILDING A BAJA BUGGY IN 40 STEPS

Team STRATOS

1. SUCCESS AT BAJA= DEDICATED TEAM +

SMART CAPTAIN + HELPFUL FACULTY ADVISOR

2. DIVIDE THE TEAM, RESEARCH, BRAINSTORM,

DISCUSS, DEBATE AND ARGUE

3. MAKE A BASE PLAN AND THEN 3D CAD

WIREFRAME

4. BUILD PROTOTYPE OF SPACE FRAME. ESP.

FOR FIRST TIMERS

5. CAD MODELS AND ANALYSIS

5A. PRELIMINARY AND FINAL MODELS

6. OBTAIN A NICE AND TIDY WORKSHOP

7. SET TABLE ACCURATELY AND MAKE

MARKINGS

8. START FROM THE BASE WITH NECESSARY

MATERIALS

9. FINALIZE AND SECURE BASE

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

11. ACCURATE EDGE PROFILES ARE CRUCIAL

12. SPOT TALENTED WELDER(S), ENCOURAGE

SUFFICIENT TRAINING AND START WELDING

12A. GOOD WELDS ARE THE SECRET OF A GOOD

CAR

13. SCHEDULE WELL THROUGHOUT

14. KEEP SPONSORS IN THE LOOP

15. ENSURE FIT OF CRITICAL COMPONENTS

16. COMPLETE FRAME

16A. NOW BRING THE FRAME TO THE DESIRED

RIDE HEIGHT. HELPS IN SUSPENSION BUILD

17. WORK ON SUB-COMPONENTS MUST BE

ATLEAST HALF WAY THROUGH

18. ALSO ARRANGE FOR ALL ACCESSORIES

19. START THE ASSEMBLY!

20. FINISH CRITICAL COMPONENTS FIRST:

A-FRONT SUSPENSION

B-REAR SUSPENSION

C-HUBS

D-STEERING ASSEMBLY

E- DRIVETRAIN

F- BRAKE LINES, TIE RODS AND INNOVATIONS

(IF ANY)

21. INSTALL THE OTHER ESSENTIALS: SEAT,

SAFETY KIT, ETC

22. ELECTRICAL AND BODY PANELS ARE

OPTIONAL AT THIS STAGE

23. TIME FOR THAT FIRST EVER TEST DRIVE!!

24. DISCUSS IMPROVEMENTS NECESSARY

25. STRIP DOWN ALL THE PARTS FOR PAINT

JOB. START BY SPRAYING RED OXIDE

26. MAKE IMPROVEMENTS TO OTHER PARTS OF

THE CAR SEPARATELY.

27. APPLY PRIMER ON THE FRAME

28. MIX PAINT WITH THINNER APPROPRIATELY

AND TRY OUT

29. NOW GIVE ATLEAST 2 COATS OF PAINT

30. RE-ASSEMBLE THE CAR

31. COMPLETE THE CAR TO THE MAXIMUM

EXTENT: BODY PANELS, INNOVATIONS, ETC

- 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

32. RUN FIELD TESTS FOR ATLEAST A MONTH

(CRITICAL)

33. MAKE YOUR COLLEGE COME TO LIFE AT 3AM

34. HOPE THINGS FAIL HERE SO YOU CAN YOU

CAN BE SAFER ON RACE DAY

35. TEST MORE AT TOUGHER PLACES.

Courtesy: Dirt Mania ATV dirt track, Kanakpura Road, Bengaluru

36. HOPE MORE THINGS FAIL AT THE RIGHT

TIME

37. REPAIR AND TEST EVEN MORE.

38. GO BACK TO GARAGE. CLEAN UP, TOUCH UP

39. SHIP TO RACE TRACK

40. KEEP TOOLS AND SPARES HANDY AND

HOPE FOR THE BEST AT BAJA!!

IF THINGS DON’T WORK OUT, DON’T BE TOO

DISHEARTENED..

..YOU MIGHT STILL GET TO WIN ANOTHER DAY!

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.

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.

MY BEST WISHES TO ALL FUTURE BAJA

ASPIRANTS!!

-Manish O.

THANK YOU!

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