The Baja must be able to accommodate a range ofdriver sizes from 95% male to 5% female. A number ofcardboard and PVC prototypes were made early on to ensure our initial designs could fit the whole family.

PROTOTYPING

CHASSISThe chassis has been designed to beeasily manufactured with single planebends and clearances for robotic MIG welders. Steel tubing with larger diameter and thinnerwalls has allowed us to reduce the weight of the vehicle significantly without sacrificing safety.

BAJA BLASTERSSAE BAJA INTERNATIONAL

SUSPENSIONThe front suspension is composed ofa double A-arm configuration. The design is easily adjustable and simpleto control the dynamic characteristics.

The rear suspension is composed of asemi-trailing arm configuration. It is arobust and easily manufactured designthat is lightweight and cost effective.

COMPONENT FEA

ANALYSIS OBJECTIVE

DESIGN

We will be competing in the SAE Mini Baja competion this May in Portland, Oregon.Our objective was to create a Baja vehicle capable of performing superbly in a numberof competition events including:

Hill ClimbAcceleration and Brake TestRock CrawlFour Hour Endurance Race

In addition to these events, our goal is to sell the vehicle design to a panel of Polaris Engineers. Our design focus was to make a car that was robust enough to survive anytrack conditions, but also easy enough to drive and work on that a family could share the experience of off-roading.

Critical Design Judging by Polaris EngineersSales PresentationManuverability Event

Clutch and CVT are easily tunable for race-day adjustments.

Water-jet cut knuckles and tabs provide for easy assembly and reduced costs.

Fox air-shocks provide a progressive spring rate for bottom-out control.

The chassis and suspension aredesigned to withstand impact loadsin excess of 9G.

DRIVE TRAINThe drive train is easily adjustable through theuse of a CVT (Continuously Variable Transmission) and variable clutch. A limited-slip differential isused for its capability of providing the most power to the wheel with most friction.

Threaded rod-end joints and lateral links used on suspension act as controlled failure points to ensure that repairs on the track will beminimal.

CV (Constant Variable) shaft travel characteristicswere taken into account to ensure peak performanceat all times on the track.