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After running into several issues with the 2016 Baja vehicle, our team wanted to make some drastic changes in order to improve the handling of the car.

Changes Made:

• Handlebar to steering wheel (with rack and pinion)
• Inboard to outboard suspensions system

Goals:

• Improve low speed maneuverability
  • Achieve  50% Ackermann
  • Minimal scrub radius
  • Minimal change between bump and droop steer

Process:

• Utilized sensors in Solidworks model
• Tracked all relevant dimensions via text file linked to sensors
  • Allowed for overall geometry to be quickly changed and analyzed
• Modeled components and perform FEA to determine lifespan
• Chose final design and created jigs for welding of suspension

Outcome:

• A vehicle that outperforms the year prior's car
  • Increased low speed maneuverability by reducing turning radius by over 30%
  • Less reported driver fatigue by reduced steering effort

Problems Overcome:

• Original A-arms interfered with shocks, mounting points spread and A-arms redesigned to fit
• Wheels could over-center under heavy turning making it impossible to return to neutral. Changed from rear mounted steering arm and rack to front mounted to eliminate issue
• saw buckling in A-arm shock mount, reduced overall length by modifying suspension geometry