Front Suspension Greg Habiak, Nicole Simon, Joe Vuto

Bill of Materials No.PartSourcePart No.QTY Weight per Part Cost per Part (Retail) Total Weight Total Cost 121x7-10 M933 Tire (Razr2 Front)Tires UnlimitedT $ $ Douglas DWT Red Label WheelRocky Mountain ATV $ $ Yamaha Raptor 125 Steering Knuckle/Hub Assembly MotoSportsOn next slide $1, Top A-armsMcMaster-Carr9056K $ $ Bottom A-ArmsMcMaster-Carr9056K $ $ " Pro ShocksSpeedway Motors582ASB510B22.319$ $ Hyperco Coil-Over Racing SpringsSpeedway Motors $59.995$ Steering ArmsChassis Shop $ Steering Arm ConnectionMcMaster-Carr8910K $ $ Chromoly Steering ColumnMoore PartsAC $ Universal Joint and BootMoore PartsAC $ $ Steering Column BearingMoore PartsAC $ $ Aluminum Butterfly Steering WheelBMI Karts $ $ Rack and PinionChassis Shop 12.74$ $ Fixture for Rack and PinionMcMaster-Carr6527K $ $ TabsMcMaster-Carr8910K $0.312$ /8" Ball jointsMcMaster-Carr6960T $ $ /8" Threaded Aluminum Weld BungsMidwest Control Products Corp.WTFA-10R $ $ /2" Bolt/NutMcMaster-Carr 40.2$ $ /2" Ball jointsMcMaster-Carr60645K $ $ /2" Threaded Aluminum Weld BungsMidwest Control Products Corp.WTFA-8R $ $ /8" Bolt/NutMcMaster-Carr 80.15$ $ /8" Ball jointsMcMaster-Carr6064K $4.591$ /8" Threaded Aluminum Weld BungsMidwest Control Products Corp.WTFA-6R $ $ /16" Bolt/NutMcMaster-Carr 40.13$ $1.40 Total 81.17$2,914

2011 Yamaha Raptor 125 Steering Knuckle/Hub Assembly PartPart No.Qty Retail Price per Part Total Cost Hub Assembly Hub, Front3GD $222.55$ Bolt, Serration $3.84$15.36 Spacer, Bearing1UY $14.84$29.68 Bearing $21.44$42.88 Bearing $21.95$43.90 Oil Seal $9.34$18.68 Oil Seal $7.14$14.28 Nut, Flange $4.19$33.52 Collar R1-002$6.04$12.08 Washer, Plate $3.25$6.50 Nut, Castle $5.45$10.90 Pin, Cotter $3.25$6.50 Cover, Plate1S $4.94$9.88 Steering Knuckle Assembly Steering Knuckle Assy, Left3GD $ Steering Knuckle Assy, Right3GD $ Total Cost$1,158.58

Rod Ends at Steering Knuckle

Parameters from Trade Study Camber = 10° Caster = 5° Kingpin Angle = 13° Scrub = 1.23 in.

Parameters from 2D A-Arm Motion Analysis Ride Height = 10.7 in. Minimum Clearance = 4.8 in. Total Travel of Tires = 11 in. Total Travel of Rod Ends = 45.3° Track Width = in.

Steering Parameters Max Turning Angle of Tire = 36.4° – Rack and Pinion has 4 in. total travel Minimum Turning Radius = tan(90°- 36.4°)*WB Wheelbase = in. Minimum Turning Radius = 7.0 ft Percent Ackermann = 0%

Exploded View of New Steering Arm Connector

Top Piece of Steering Arm Connection

Bottom Piece of Steering Arm Connection

Parameters from Force Analysis Shock Force at Full Compression = ( , , ) lb f – Calculated assuming car landed on only two wheels (275 lb f acting on one tire) and shocks are fully compressed. Maximum Centripetal Force = (-112.5, 0, 0) lb f – Assuming 1g for centripetal force experienced on car, with 50% acting on the front, 90% of that acting on one tire, and 50% of that acting on one a- arm. Maximum Braking Force on Bottom A-Arm = (0, 0, ) lb f – Calculated from maximum braking torque according to Brakes Maximum Braking Force on Top A-Arm = (0, 0, ) lb f Where X is normal to the right side of the toe box, Y is normal to ground, and Z is normal to the front of the car.

Top A-Arm FEA with heat treated 6061 Max Stress = ksi Safety Factor = 2.56 Max Deflection = in.

Bottom A-Arm FEA with heat treated 6061 Max Stress = 9.27 ksi Safety Factor = 3.23 Max Deflection = in.

Bottom A-Arm FEA without heat treatment Surpasses the yield strength of 6061-O, but not the tensile strength Not accurate because the majority of the a-arms will be stronger material and able to take the applied force. Plan to build aluminum a-arms to test and steel a-arms as backup Steel a-arms add lbs to FS weight. Brings total weight to 86 lbs. > 8 ksi