1. Ben Gruenzner Nick Hanson Aaron Pilger Dustin Kalhoff Chris Kost Jason Kuenzli Justin Moe Scott Rector Mike Schmitz Jamie Schlachter Ryan Schommer Ryan Stebbins Paul Steevens Mike Tichy Faculty Advisors: Dr. Bruce Jones and Mr. Gary Mead Maverick Motorsports 2005 Car# 28

2. Purpose of the Event  Conceive, design, fabricate, and compete a formula-style car Low cost Easy to maintain Reliable High performance  Knowledge and creativity is challenged because of chassis and engine restrictions  Gain experience in a meaningful engineering team project

3. Competition Events Static Events Technical Inspection No points Cost and Manufacturing Analysis 100 points Presentation 75 points Design 150 points -------------------------------------------------------------------- Total 325 points Dynamic Events Acceleration 75 points Skid Pad 50 points Autocross 150 points Fuel Economy 50 points Endurance 350 points -------------------------------------------------------------------- Total 675 points

4. 2005 MSU FSAE Goals  Manufacture a reliable car that will finish each FSAE event Simple design Easily manufactured and assembled  425 lb weight  Increased performance acceleration, braking, and handling  Create a documentation binder for future teams to follow  Better engine package  Improved driver positioning  Repeatable decision methods

5. Decision Matrix Wheel Decision MatrixWeightPerformance Cos tReliabilityBrake Line Routing Tota l Weighting57241 Keizer Mag4424568 Keizer Aluminum5354572 Sander Engineering D-Mount2225048 Real Wheels5452071

6. Engine  Honda F4i 598cc 4-cylinder engine  Naturally aspirated  Converted to run on E-85 ethanol  Performance Electronics Engine Management System

7. Intake Design Single Plenum Design 19mm Restrictor Heimholtz Calculations

9. Exhaust Design Only Scott Knows

11. 3-31-05 FSAE Dyno run 3

12.  6 speed, cockpit shifted manual transmission  Interchangeable drive Torque proportioning differential Direct drive aluminum spool  Custom RCV drive axles  Drive sprocket and chain driven Drivetrain

13. Chassis  MIG welded 1020 steel tubing and 1020 square tubing on the rear differential box  FEA Beam Structure Design engine as a semi-stressed frame member rear box removable for easy engine servicing  11.4” vertical center of gravity  48% Front / 52% Rear weight distribution  50%-50% left-right balance

14. Brake System  One dual piston caliper on each front wheel  One four piston caliper on the rear drive shaft  Two master cylinders: one to control the front brakes and one to control the rear brake

15. Steering System  12:1 Steering ratio  Less than 1/16” of Bump  30° of total steering  67% Ackerman Angle  Track width: 47” front and 45” rear

16. Suspension  Custom machined uprights and hubs  Double, unequal length A-arms  Pushrod actuated spring/damper  2.00” of total travel  SusProg3D software used to simplify component placement  66” wheelbase  Minimal camber change  Low roll center  Rising Spring rate

19. Upright Designs Aluminum FEA Design –FEA Picture

20. Tires and Wheels  13” x 6” Keizer spun aluminum rims are used allows more room for packaging chosen because of weight and cost  20X6.5-13” Tires Goodyear Slicks and Rain Tires

21. Documentation Design Report Document Binder

22. Vehicle Cost Brakes System804.46 Engine and Drivetrain4985.44 Frame and Body767.41 Instuments and Wiring1147.83 Miscelaneous Fit and Finish110.74 Steering System525.74 Suspension and Shocks2350.95 Wheels and Tires1177.34 Total11869.92

23. Any Questions?