1. Front Suspension Greg Habiak, Nicole Simon, Joe Vuto

2. 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 UnlimitedT682400210$114.0520$228.10 2Douglas DWT Red Label WheelRocky Mountain ATV108762002824.9$77.009.8$154.00 3 2011 Yamaha Raptor 125 Steering Knuckle/Hub Assembly MotoSportsOn next slide24.6-9.2$1,158.58 4Top A-armsMcMaster-Carr9056K76221.0667$25.072.1334$50.14 5Bottom A-ArmsMcMaster-Carr9056K76221.5748$25.073.1496$50.14 65" Pro ShocksSpeedway Motors582ASB510B22.319$178.994.638$357.98 7Hyperco Coil-Over Racing SpringsSpeedway Motors44414-10022.5$59.995$119.98 8Steering ArmsChassis Shop60-1-08320.362316.41250.7246$32.83 9Steering Arm ConnectionMcMaster-Carr8910K65320.7984$4.801.5968$9.60 10Chromoly Steering ColumnMoore PartsAC425010-311$34.001 11Universal Joint and BootMoore PartsAC425261-110.75$40.000.75$40.00 12Steering Column BearingMoore PartsAC42501410.25$18.000.25$18.00 13Aluminum Butterfly Steering WheelBMI Karts60068011.5$44.991.5$44.99 14Rack and PinionChassis Shop 12.74$327.952.74$327.95 15Fixture for Rack and PinionMcMaster-Carr6527K13413.05$10.663.05$10.66 16TabsMcMaster-Carr8910K395200.1$0.312$6.20 175/8" Ball jointsMcMaster-Carr6960T2140.47$26.181.88$104.72 185/8" Threaded Aluminum Weld BungsMidwest Control Products Corp.WTFA-10R-0.99540.33$4.781.32$19.12 191/2" Bolt/NutMcMaster-Carr 40.2$0.200.8$0.80 201/2" Ball jointsMcMaster-Carr60645K85280.37$7.282.96$58.24 211/2" Threaded Aluminum Weld BungsMidwest Control Products Corp.WTFA-8R-0.99480.33$4.692.64$37.52 223/8" Bolt/NutMcMaster-Carr 80.15$0.301.2$2.40 233/8" Ball jointsMcMaster-Carr6064K83240.25$4.591$18.36 243/8" Threaded Aluminum Weld BungsMidwest Control Products Corp.WTFA-6R-0.79540.33$6.971.32$27.88 255/16" Bolt/NutMcMaster-Carr 40.13$0.350.52$1.40 Total 81.17$2,914

3. 2011 Yamaha Raptor 125 Steering Knuckle/Hub Assembly PartPart No.Qty Retail Price per Part Total Cost Hub Assembly Hub, Front3GD-25111-20-002$222.55$445.10 Bolt, Serration90114-10006-004$3.84$15.36 Spacer, Bearing1UY-25117-00-002$14.84$29.68 Bearing93306-00446-002$21.44$42.88 Bearing93306-20231-002$21.95$43.90 Oil Seal93105-26026-002$9.34$18.68 Oil Seal93102-22216-002$7.14$14.28 Nut, Flange95704-10500-008$4.19$33.52 Collar90387-150R1-002$6.04$12.08 Washer, Plate90201-14220-002$3.25$6.50 Nut, Castle90171-14002-002$5.45$10.90 Pin, Cotter91490-30030-002$3.25$6.50 Cover, Plate1S3-25127-01-002$4.94$9.88 Steering Knuckle Assembly Steering Knuckle Assy, Left3GD-23501-10-001$234.66 Steering Knuckle Assy, Right3GD-23502-10-001$234.66 Total Cost$1,158.58

4. Rod Ends at Steering Knuckle

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

6. 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 = 53.625 in.

7. 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 = 61.79 in. Minimum Turning Radius = 7.0 ft Percent Ackermann = 0%

8. Exploded View of New Steering Arm Connector

9. Top Piece of Steering Arm Connection

10. Bottom Piece of Steering Arm Connection

11. Parameters from Force Analysis Shock Force at Full Compression = (271.774, -387.566, 83.466) 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, -520.3) lb f – Calculated from 1040.625 maximum braking torque according to Brakes Maximum Braking Force on Top A-Arm = (0, 0, -416.3) 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.

12. Top A-Arm FEA with heat treated 6061 Max Stress = 11.72 ksi Safety Factor = 2.56 Max Deflection = 0.023 in.

13. Bottom A-Arm FEA with heat treated 6061 Max Stress = 9.27 ksi Safety Factor = 3.23 Max Deflection = 0.035 in.

14. 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 4.654 lbs to FS weight. Brings total weight to 86 lbs. > 8 ksi