Stevens Formula SAE

Cost Report Submitted

2010-04-01T12:02:00.000-07:00

Yesterday the team mailed in the cost report completing all of the paperwork for this years competition. At 256 pages it was quite a project. Thankfully last years team set up a great system for us to use to get it done, thanks Billy. With all the paperwork done the team can focus solely on the car. With a lot of work to do the team is working fervently and everyday that passes we can see the car getting closer to completion. The goal right now is to get the car completed, take it apart, paint it, and put it back together by the end of the month to have it ready for the Stevens Car Show on May 2nd.

SAE Car Show -- May 2nd

2010-03-29T17:22:00.000-07:00

Stevens Formula SAE and Autism Speaks will be co-sponsoring a Car Show on May 2nd on the Stevens Campus. The team will be revealing the 2010 car at this event and would like to invite everyone to attend.

It's Starting to Come Together

2010-03-27T17:10:00.000-07:00

The team has been hard at work in and out of the shop. On the car front we were able to get all of the suspension members mounted this week. We also received the front uprights from George Wohlrab, the schools machinist, which came out great and mounted right up. We also settled on a plastic for the body panels, PETG. This material is lightweight and easy to form and should make an excellent body. In addition to the work in the shop we have been finalizing our cost report. The cost report is a document which calculates the cost of manufacturing 1000 cars in one year. The team did very well on this report last competition and are looking to continue the good work. All in all it has been a very productive week with more assemblies being put on its beginning to look like a car. The next steps are to get the differential mounted, the axles cut and fitted, and get the new engine running.

The car with all the suspension arms on and tires mounted to two wheels.

Rear suspension arms, upright, and toe adjust.

View from the front of the car.

Front suspension arms, upright, and hub with tire mounted.

2010-03-11T09:44:00.000-08:00

The team has been hard at work making progress on every sub-assembly of the car. All of the rear engine mounts have been fabricated and fitted. We are working on designing and installing the front mounts, which will utilize the stock R6 mounting plates for easy installation and removal of the engine. The team also fabricated the mounts for the pedals and designed an adjustable seat for this years car. We also finalized the design for the body which will consist of three plastic body panel and a fiberglass nose. The plastic panels will be along the sides of the car and one over the front to act as a hood. The fiberglass nose will cover the impact attenuator. The picture below will give you an idea of where the plastic panels will be. With tons of work still to do on the car we are planning on working over spring break, next week, to get the car done in time. The goal for the coming week is to have all of the mounts for the different components installed and hopefully have a rolling chassis. We are also hard at work on the Cost Report another critical piece of the competition. The cost report is based on a production run of 1000 cars in one year. The team must cost all aspects of the car down to the installation of the nuts and blots. Last years team was able to place 15th in this event and with their help we hope to do just as well. We have a lot of work ahead of us, but are confident that this years car will be the most competitive in school history.

Pedals mounted in the car

Pedal mounting plates

Finished rear engine mounts

Body panel mock-up
The big board with all of the tasks

Suspension and Engine Progress

2010-03-05T13:38:00.000-08:00

The team has made lots of progress since the last post. We have completed all of the suspension arms and are working on the frame mounts. Fabrication of the rear knuckles has also begun. They have been jigged and are in the process of finish welding. After the engine failure last week the team scrambled to find a new engine and in the process made contact with Bay Cycles in Bayonne. With help from them we have found a new R6 engine to put in our car. With this great news we are working on mocking up the engine mounts with our old engine, while awaiting the new one. We are at the point where all of the components we have designed are coming together and we are starting to see the fruits of our labor.

Suspension Arms

Rear Knuckles getting welded

Rear Engine Mounts

Action Deadline 1 Met

2010-03-01T16:51:00.000-08:00

The team has successfully submitted the first round of Action Deadline material to the Formula SAE judges. This includes the Impact Attenuator Data, the Design Report, and the Design Spec Sheet. The major piece of this was the Impact Attenuator Report. For this the team had to design and build a device to limit the forces on the driver in the event of a front end collision. Our design was a box filled with aluminum honeycomb sheets. To test our design the team dropped a 417 kg weight from about 6 feet on the the attenuator. Data was collected and our design passed with flying colors, to see a video of the test click here.

New impact attenuator

Attenuator in position for test.

Crushed attenuator after the test.

Engine Failure

2010-02-21T12:41:00.001-08:00

The team suffered a major setback last week with the failure of our Yamaha R6 engine. During a test run last Wednesday white smoke began pouring out of the exhaust and we knew something was wrong. Upon further inspection we found that one of the connecting rods had broken and seriously damaged a cylinder ans one of the valves. Unfortunately we will not be able to salvage this engine and are looking for another. The team will continue to build the car while we hunt down another engine. We are confident that we can still make it to competition and be competitive.

Some of the carnage

Engine Work

2010-02-10T10:27:00.000-08:00

The engine team has been working hard to get the engine up an running. They have been searching through the wiring harness finding all the connections that are no longer needed and making alterations so the engine will work outside the bike it came from. The engine has been hooked up to the radiator and the fuel lines. The team hopes to have the engine running by early next week.

Some of the team looking over the wiring harness.

Engine hooked up to the fuel system.

Chassis Finish Welded

2010-02-10T09:59:00.000-08:00

The team got the chassis back from finish welding on Monday night. Thanks again to Majka Railing in Paterson, NJ for the awesome work and great turn around. Below are a few pictures of the finished chassis. The team is continuing work on the suspension members and the mounting points for the engine.

Chad having some fun with the new chassis.

Control Arm Fabrication

2010-02-08T08:14:00.000-08:00

With the chassis out for welding the team has begun working on the suspension components. Jigs for the upper and lower control arms for the front and rear have been built. The team is in the process of fitting all of the members together. Once the members are fit the team will send some of the components to George Wohlrab who runs the machine shop on campus to be drilled and tapped. The goal is to have the suspension components together by early next week.

A part of the control arm which will be tapped to accept a heim joint.

A front upper control arm fit into the jig.

2010 Chassis Together

2010-02-03T10:45:00.000-08:00

View from the drivers compartment

View from the rear of the chassis

Side View

The 2010 chassis is fully tacked together and is ready for finish welding. The chassis will be sent to Majka Railing in Paterson, NJ for this final process. Hopefully we will have it back in about two weeks and can start assembling the rest of the components. With the chassis out for welding we will be working on the suspension components and the engine. The plan is to have these finished and ready to install when the chassis returns.

Engine Testing

2010-02-03T05:37:00.001-08:00

Setting the Engine up for bench testing. Should be running by the end of next week and ready for tuning.

Chassis Fabrication Pictures

2010-02-03T05:26:00.000-08:00

View from rear of the chassis

Right side view of the chassis

Front view of the chassis during fabrication

2010 Car Update

2010-01-25T08:39:00.000-08:00

After a successful competition appearance in 2009, the Stevens Formula SAE Team is working on a completely new car for the 2010 Michigan competition. With the experience gained from last year, the team is eager to build a better, more competitive car for this year. With the departure of the 2009 senior design team, a new group has taken on the project and is making great progress. The new senior design team is comprised of six seniors: Brandon Murphy, Chad Edwards, Fidelio Sime Segura, John Cheney, Matt Gordon, and Tom Paddack. Their hard work in the fall semester has gotten the team into a great position to be very competitive in Michigan this year.

At this time, most of the chassis has been tacked together and will soon be taken to Majka Railing, a sponsor based in Paterson, NJ, for help with finishing the welds. The team has also been working on the engine for this year’s car, which is a Yamaha R-6. They are beginning to modify the motorcycle’s original engine harness for use in the car. The team’s next goal is to machine the hubs and fabricate the other suspension components.

With a lot of work ahead of them, the team is confident that this car will be one of the most competitive in school history.

2010 Chassis Fabrication Photos

2010-01-25T08:32:00.000-08:00

John making sure everything is level and square.

Frame rails and supporting cross members tacked together.

Brandon using the tube notcher.

Michigan FSAE Photos (Part II)

2009-05-28T14:18:00.001-07:00

In the pits before the Endurance Race. ( Tightening the lugs, because seconds before another teams car on the track lost a wheel!)

Shot from the infield fence.

Tom taking some tight turns

The Whole Team

The Senior Design Team

Michigan FSAE Photos (Part I)

2009-05-28T13:53:00.000-07:00

In Reverse Order:

1. We placed 15th for the Cost Report!
2. Working on the car in the paddock
3. Passing Sound and getting ready to pass Breaking.
4. We passed all 3 parts of tech inspection and hit the track in the rain.
5. I get the green flag for the Auto Cross.

Competition Ready

2009-05-04T18:01:00.000-07:00

assembly v1.0

2009-04-17T02:38:00.000-07:00

Come see the car this Sunday at Presidents Tea, 4/19/2009 , 2-4 PM on Humphreys Lawn at Stevens Institute of Technology.

More Pictures:
http://www.stevens.edu/fsae/av1/

Presidents Tea Prep

2009-04-14T14:33:00.000-07:00

We are getting ready for Stevens open house this Sunday, 4/19/2009
We have the chassis & exterior getting painted and the wiring final touches.

Auto Racing Speaker Series

2009-04-13T21:24:00.000-07:00

More info at http://howe.stevens.edu/index.php?id=1757

Cost Report Submitted!

2009-04-03T00:44:00.000-07:00

280 pages, $9,865.
The paper work is complete and focus is 100% on the car. We have crashed the schedule to get it ready for Presidents Tea on April 19th. The exterior should be complete as well as the suspension so we should have a nice rolling chassis. The engine is being wired to our megasquirtV2.0 .

Spring Break Update

2009-03-12T15:36:00.000-07:00

A large amount of work has been accomplished has been accomplished during the first half of spring break.

We got the chassis back from welder Part2.
We have gotten a number of body panels completed; and the fiber glass should be ready to be prepped and painted tonight. [can see it in the background]

IA Crush tester

2009-02-27T17:42:00.000-08:00

Impact Attenuator

2009-02-25T11:59:00.000-08:00

The Impact Attenuator [bumper] was built and tested.

A Few Photos

2009-02-23T15:13:00.000-08:00

Steering & Safety

2009-02-13T00:10:00.000-08:00

<-Steering

Safety

Fiberglass v3.0

2009-02-13T00:02:00.000-08:00

Fiber glass mold

Fiberglass attempt 3.0

Getting the 01 GSXR 600 Motor setup for testing

2009-02-12T09:49:00.000-08:00

The old 2001 GSXR 600 motor has been rebuilt and been set up in the 04 chassis for testing.

Schedule update

2009-02-09T21:53:00.002-08:00

After a very productive meeting; our revised schedule is published : calendar

Camera is working, PICS soon

2009-02-09T21:53:00.001-08:00

Update

2009-02-06T19:26:00.000-08:00

Stute article published today; great press. Excellent and well written article, many thanks to Melissa Weigand for her talented editorial and the help with the front suspension.
-Front suspension tacked and ready to be finalized

-Engine mounted in old chassis, awaiting a battery tender, fuel pressure regulator, and fuel.
-confident this engine will purrr in the next few days

-Order received today; allows the beginning of the Impact Attenuator fabrication and a few other projects.

-Fiberglass still in the works

Groundhog Day

2009-02-02T19:35:00.001-08:00

The rack & pinion was relocated and tacked; this was done to allow for proper leg clearance and Figure 9 of the rule book.

The suspension is being positioned, one tab at a time...

Formula Student Info

2009-02-02T12:46:00.000-08:00

Youtube video describing the competition
http://www.youtube.com/watch?v=SH3H5bsvI0g

Meeting Location

2009-01-30T10:51:00.000-08:00

SHOP TIMES: The shop is open for members to work on the car every weekday and on Saturdays during the times listed below. If you are interested in working on the car please stop by the shop at any of these times.

Monday: 5pm to 8pm
Tuesday: 2pm to 5pm
Wednesday: 5pm to 8pm
Thursday: 2pm to 5 pm
Friday: 11am to whenever you need to leave

Saturday: 2pm to 5pm

ENGINE!

2009-01-29T19:49:00.000-08:00

The mess that some called a wiring harness was figured out today, hooked up to a battery and...
the Engine turned over!
this week we want to secure it, put some fuel and radiator on it and see if it runs

The mounting points for the 5point harness are ITW; some clarification on the rules are needed.

Too busy in the shop to remember to update

2009-01-28T22:14:00.000-08:00

We have made some great progress in the 3weeks since last post.
Camera broke :( hope for some new pics up soon.

Exhaust is well on its way thanks to the very generous work and donations by Richie from
http://www.europeanexchange.com/
It is greatly appreciated

Fiberglass has seen the mold created and shaped.
The first attempt at learning to fiberglass is underway; some great results are developing

The braking problem previously mentioned has been solved and is awaiting the purchase of a new pedal assembly. We should not be receiving the 35 point penalty.

The engine was finished being rebuilt, with intake attached. Are attempting to figure out the wiring harness and ECU; but will probably need to wait till the new one arrives.
-Second engine ordered and on the way

I was interviewed today by Melissa from the Stute and there should be an article in the next weeks student newspaper. This should increase awareness and participation in the project. There are many systems underway and we are well prepared for the new members.

Chassis complete

2009-01-06T09:30:00.001-08:00

Chassis re-design has been completed. This was done to allow room for fuel tank and differential. Awaiting the arrival of mounting tabs that have been delayed in shipping.
Fiberglassing the exterior is In The Works.

Welder

2008-12-28T14:16:00.000-08:00

The chassis has been taken to the welder, it should be ready for tabs and the first fitting of parts by 1/4/09.
In the mean time, we shall be working on the exterior fiberglass.

Chassis Milestone

2008-12-23T19:46:00.000-08:00

The corrected chassis is ready for the welder this week.

Formula SAE on Speed TV

2008-12-10T11:33:00.001-08:00

Link: http://www.youtube.com/watch?v=wY4QiAXGS8U&feature=related

Progress update

2008-12-03T14:01:00.000-08:00

The frame is nearly ready for the welder!
We have cut off all the bad members + tabs & polished it up. We have the new members cut and sent to the machine shop for exact angle cuts. The back frame box is tacked together and ready to accept the final supports when ready. We hope to have the frame welded and finished by Dec15th or so.

The engine has been cleaned, with new seals and completely rebuilt.

There was a problem with the braking system design; the force required to lock the wheels [80lbs] would not be acceptable, as well as the placement of the braking master cylinder would not comply with section 7.3 of the rules, requiring a template of a certain size to pass through the passenger compartment. We plan to re-work the braking design and probably need new master cylinders.

Design Work

2008-12-01T20:37:00.000-08:00

A milestone created at the beginning of this project was to have the design completed for December 1st. We have nearly succeeded. The majority of the systems are finalized and parts being ordered this week. The next few weeks we will be finishing up fabrication and begin assembly shortly after XMas.

Journal Entry 1

2008-11-23T23:22:00.001-08:00

Beginning of blog.
More to come soon!

www.stevens.edu/fsae