BIRLA INSTITUTE OF TECHNOLOGY

SRIJAN

FORMULA SAE ITALY 2013 - PROJECT

REPORT

BEGINNING: WHY FSAE ITALY

The answer to this question can be derived
from one of the primary motive of Team
SRIJAN i.e. to learn and grow.
After its formal formation and its participation
in an International competition in the year
2007 in Silverstone U.K, the team collapsed
and there was no substantial activity till the
year 2010. In that year the team was revived
and a car was fabricated to participate in a
national competition, SUPRA SAE 2011 which
was held in Chennai. The team took valuable
lessons from this endeavor and participated
for the second continuous year in SUPRA SAE 2012 held in Buddh International Circuit, Noida.
The 2012 car was built with lot of conviction, dedication and hardwork. Scientifically designed and
manufactured, it was a sincere and concentrated effort and was truly a Teams car.
But the manner, in which the entire Noida event
was conducted and judged, barely had any scope of
learning. Without any moral principle governing the
event, it was conducted just for the sake of it. The
management was next to none, the judges were
inexperienced and the judgment was biased.
Moreover, it was really disheartening for us that we
got no appreciation for our technical design and
immaculate execution especially when we had the
lightest tubular space frame in the competition.
One thing was quite clear from our 2012 calendar that Indian Formula Student competition had a
lot to catch up to be at par with its Internal version: Formula Society of Automotive Engineers
(FSAE).

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Hence, in order to learn and grow, be judged by experienced well informed judges and industry
experts, to experience the International competition level and our standing relative to it, we chose
to participate in FSAE.
We came to the conclusion that in order to design and manufacture a car suitable for an
International competition, we need at least a years time. As a result, out of the numerous
countries in which FSAE competitions are conducted, we chose ITALY as the event dates gave us
just the right amount of time.
Hence, we decided to participate in FSAE ITALY.

TEAM FORMATION
After the 2011 competition, most of the team members didnt continue. So for the 2012, National
event a new team was formed which formed the core team committee for the 2013 event.
The SUPRA SAE 2012, taught us a lot of things that needed to improve with regards to the team
management and its structure. Claude Roulle, an eminent FSAE judge in one his numerous video
lectures had emphasized the importance of Having an A class team with a C class car for first year
participants. Various forums on FSAE also discussed the importance of having quality team.
Based on these learnings, a lot of stress was laid on having a proper team structure. Sub teams
were formed with clear cut aims. And above all, it was decided that the objective would be to build
a reliable and sturdy car that would be able to clear the technical inspection and the dynamic
events. The performance parameter was given the back seat.
For the team to benefit and learn from an event, it is important that the team continues year on
year with the majority of its members. Hence, the 2013 team had 2 senior members from 2009
Batch, 5 members from 2010 Batch, 15 members from 2011 Batch and various interns from 2012
Batch. Various written tests and interviews were conducted to select the 2012 Batch interns as well
as some members from the 2011 Batch.
Apart from having a sound technical team the importance of having an efficient management team
was also recognized and efforts were made to select people who would especially be in team for its
management. This team had various functions to perform. Maintain relations with the past

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sponsors, find new sponsors and fund raising opportunities, maintain and update the site and the
teams Facebook page etc.
For the first time, a management team was formed.
Thus, the final team had 17 members in the technical team and 5 members in the management
team.

TEAMs APPROACH
The objective was clear from the beginning: To build a simple and reliable car that could clear the
technical inspection as well as the dynamic events. From our previous endeavor, one thing was
clearly evident that the team should have suitable sufficient testing time to iron out any flaws
before the event itself.
As a result, we refrained ourselves from focusing too much on the performance factor and did not
indulge in experimenting with new technological systems. Instead, we concentrated on improving
our manufacturing and designing of components that are easy to machine and assemble.
To gauge the progress of the team as well as decide the course of action, frequent team meetings
were conducted. At least two technical meetings and one management meeting was conducted
every week so that depending on the teams progress and requirement, required steps could be
undertaken.
The team had the Captain, Vice-Captain and the Team Manager who were responsible for leading
the team, handing out responsibilities and periodically checking the progress. Various sub teams
had their individual heads that would take final decisions on behalf of their team and report directly
to the captain.
We also realized that to have more and more ignited minds in our team, we need to create a
culture, understanding and passion for automobiles. For this, we conducted various workshops on
basic and advanced automotive principles. We regularly update our Facebook page with the latest
automotive news and technology.

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Each sub-team was asked to prepare an IF-ELSE OBJECTIVE sheet. Based on the end objective,
each sub team has its own requirements. But depending on the prevailing condition, financial
status, time, these requirements get modified and hence the above sheet. Its purpose was to
indicate the team to change the plan of action if a certain short term objective could not be
achieved due to any factor.
The interns were regularly asked to give technical presentations in front of the entire team so that
they are aware of the various systems, teams technical requirements and simultaneously improve
their speaking and presentation skills.
Hence, a scientific and exhaustive approach was followed and is still in progress to achieve our
primary aim of having an A CLASS TEAM.

THE FINAL CAR DESIGN

ENGINE AND POWERTRAIN: The air intake system of the ROYAL ENFIELD 500cc EFI engine was
completely redesigned using RICARDO ENGINE
SIMULATION software so as to negate the power
loss as a result of a 20mm restrictor which was
purchased from AT THROTTLE BODY.
The EXHAUST SYSTEM was completely based on
manual calculations and was constructed in
house.
QUAIFEs LIMITED SLIP DIFFERTIAL was used
along with the HALF SHAFTS, CV JOINTS and SPROCKET from TAYLOR RACE ENGINEERING to
power the wheels. The SPROCKET size was determined using the manual calculations and
OPTIMUM LAP SOFTWARE.

VEHICLE DYNAMICS: TTX OHLIN DAMPERS were used along

with machined ALUMINIUM BELLCRAKS, UPRIGHT and HUBS.
All the aluminum components were designed using
SOLIDWORKS SOFTWARE.
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OPTIMUM K software was used to determine the suspension hard points for setting up the A
ARMS.

FRAME and ERGONOMICS: An exhaustively triangulated and rigid frame, constructed of SAE 1018
steel was designed using SOLIDWORKS SOFTWARE.
A combination of MIG WELDING and ARC WELDING
was done by the team itself to build the frame.
The manufacturing of the frame was done using
machined fixtures made from MDF Board. This
allowed us to fabricate a frame with great accuracy
The drivers seat was also manufactured in-house
using FIBRE REINFORCED PLASTIC.

BRAKES: TILTON BRAKE PEDAL assembly and MASTER CYLINDERS along with WILWOOD CALIPERS
and TVS FLAME BRAKE ROTORS were used. All the brake calculations were done manually and an
excel sheet was prepared for determining the required brake pressure.
STEERING: The steering system was designed for 100% Ackerman Geometry using SOLIDWORKS
SOFTWARE. All the calculations such as reduction in bump steer and steering effort were done
manually.

ELECTRONICS: The wiring for all electronic components of the car was done in the workshop itself.

WHEELS and TIRES: Custom made, lightweight ALUMINIUM FORMRACE wheels were used along
with HOOSIER SLICK TIRES.

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BODY: An aerodynamic body was designed using SOLIDWORKS and was constructed from FIBRE
REINFORCED PLASTIC.

PROBLEMS FACED:
The toughest challenge was to gather sufficient funds for meeting our project budget which was
around 14 Lakhs.
In the month of January 2013, an amount of ` 1.12 Lakhs was paid for teams registration. For this,
the members contributed from their own pocket. Our team was promised a substantial
contribution during the Golden Jubilee meet of the 1962 Batch, held in the month of December
2012. But due to some misunderstanding and lack of communication between the alumni, we
didnt receive any funds till late May 2013.
During this period i.e from September 2012 May 2013, team members were deeply engrossed to
gather funds so that this project could remain afloat. Hence, a lot of useful time was wasted in
these sponsorship efforts which could otherwise have gone into design improvisation.
Secondly, this delayed funding, didnt allow us to order some important components. This
procurement delay hampered our manufacturing, severely. We could have started our fabrication
work much earlier and would have had sufficient testing time had we received our promised funds
a bit earlier.
It was only with the help Mr B.B Pant, our Training and Placement Department Head and our
sincere and persistent efforts that we were able to convince our alumni that this project was
indeed worthy of their attention. Only in June 2013, did we start receiving funds.
After we started ordering our components upon getting the required funds, we were faced with
some bizarre and unexplainable situations. We could not order steel tubes from our chosen vendor
in Mumbai due to an unforeseen traders strike. The courier service that transported our tubes
from our Chandigarh vendor, refused to deliver it to the Bangalore based factory where the tubes
were to be laser cut, even after reaching there. It was due to some receipt fault on the part of the
vendor. After the tubes got cut in Bangalore, they were air couriered to us by that factory in two
boxes. One box became untraceable during the transit and was delivered to us at a very later stage.
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We ordered our driveline components from a U.S.A based company. Upon receiving the package
we found it to be torn at ends and some components were missing. Some aluminum components
that were CNC machined were damaged beyond repair as they were incorrectly machined. It was
all due to the inexperience of the Production Head at the Dumka tool room.
But, like the many odds that we faced in the past, we did survive this time also due to our sheer
perseverance and tremendous support from our faculty advisor, Dr Jeeoot Singh.
It would have been almost impossible for us to accomplish this feat had Dr Jeeoot Singh not been
our Faculty Incharge. He ensured that the college authorities pay heed to our requirements and
communicated on our behalf. It was because of him that we got the college to fund us with ` 2.00
Lakhs just days before the event.
At the same time, we got strength and support from Mr Sanjay Khemkha, owner of Pensol
Industries and Mr Atul Prasad alumnus from the 2006 Batch. Their financial support at such a
crucial juncture helped this project to stay afloat.
Inspite of all the difficulties faced, we were able to manufacture our car, BMR-051 within time and
were able to ship it successfully. However, due to a delayed start, our manufacturing suffered
severely and we had only a months time to fabricate a running car from scratch. As a result, we
could not test the car to our expectations.

DETAILED REPORT ON FUNDS:

Attached with the report is a detailed listing of how the funds were obtained and where were they
utilized.

SPONSORSHIP AMOUNT FOR TEAM SRIJAN FSAE ITALY 2013

1. From college
Total Amount

` 2,00,000

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2. From Sponsors:
SL. NO.
1.

NAME OF THE
SPONSOR
Central Coalfields Limited

2.

Vasundhra Homes

` 50,001/-

Payment received through

cheque no. 709588.

3.

Jharkhand Small Industries

Association (JSIA)

` 25,000/-

Payment by cheque.

4.

Indian Oil-Servo

` 25,000/-

Payment received through

cheque no. 02025506.

5.

USA Jockey

` 10,000/-

Payment by cash.

S G Enterprises

` 25,000/-

Payment received via

Cheque

7.

Pensol Lubricants

` 50,000/-

Payment received via

Cheque

TOTAL

AMOUNT
SPONSORED
` 50,000/-

REMARKS
Release order received.
Payment pending.

` 2,35,001/-

3. From Alumni:
SL. NO.
1.
2.

NAME OF THE
ALUMNI
Mr. S. N. Agarwal
Mr. Abhinav Omar

AMOUNT
SPONSORED
` 3,50,000/` 5,500/-

3.

Mr. Kaushlesh Maheshwari

` 5,000/-

4.

Mr. Sidharth Malik

` 10,000/-

5.
6.

Mr. R. N. Vyas
Mr. Vishal Gupta

` 10,000/` 22,000/-

REMARKS
Payment received through TnP
Payment through NEFT on
03/04/2013 and 28/05/2013
Payment through NEFT on
06/02/2013.
Payment through NEFT on
07/03/2013.
Payment through cash.
Payment through NEFT on
19/03/2013, 08/04/2013,
01/05/2013.
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7.

Mr. S G Sureka

` 1,75,000/-

Payment received through TnP

8.

Mr. G K Gupta

` 35,000/-

Payment received through TnP

9.

Mr. Samir Kumar Sadhu

` 35,000/-

Payment received through TnP

10.

Mr. Madan Agarwal

` 98,000/-

Payment received through TnP

11.

Mr. Prakash Sacheti

` 50,000/-

Received in SAE Account

12.

Mr. D Hada

` 35,000/-

Payment received through TnP

13.

Mr. R P Jain

` 35,000/-

Payment received through TnP

14.

Mr. Vishal Gupta

` 10,000/-

Payment received by NEFT

15.

Mr. Atul Prasad

` 50,000/-

Payment received by NEFT

` 9,25,000/-

TOTAL

4. From Ignite intent (Crowd Funding)

Total Amount Collected

` 8,000/-

Total Sponsorship amount = ` 2,00,000 + ` 2,35,001 + ` 9,25,000 + ` 8,000

= ` 13,68,001

DEPARTMENTAL BUDGET
S.NO.

DEPARTMENT

Vehicle Dynamics

Engine

COMPONENT
Aluminum
Wet tires
Machining
Bearing
Damper Rebuilding
Royal Enfield 500cc
Throttle Body
Exhaust

COST (MARKET
))COST)
` 70,000
` 20,000
` 1,50,000
` 10,000
` 40,000
` 1,00,000
` 40,000
` 4,000
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Aluminum
Steering
Rack
U-Joint
Quick Release
Brakes
Caliper
Fittings and Lines
Rebuild Kit
Differential, Sprocket
Drivetrain
& Chain
Chassis
Tubes
TIG Equipments
Fixtures
Safety Equipment
Driver Suit
Shoes
Balaclava
Neck Support
Arm Restraint
Electrical & Electronics ECU
Wiring and taping
Power tools
Bodyworks
Brochures
Management
Flex, Newsletters

5
6

8
9
10
11

TOTAL

` 1,000
` 17,000
` 5,500
` 4,500
` 10, 500
` 9,500
` 2,000
` 1,62,000
` 11,000
` 6,000
` 30,000
` 35,000
` 4,000
` 2,700
` 1,700
` 1,700
` 20,000
` 5,000
` 15,000
` 30,000
` 10,000
` 10,000
` 8,28,100

TOTAL COST= Components market cost + Custom on Import (30%) + Component Shipping
Cost
= ` 8,28,100+ ` 85,830+ ` 55,000= ` 9,68,930

MANUFACTURING COST
SL. NO

COMPONENT

COST
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Uprights

` 50,000

Hubs

` 50,000

Wishbone Inserts

` 24,000

Wishbone clevis

` 10,000

Welding

` 5,000

Cutting Blades

` 10,000

Fasteners

` 5,000

Tube Bending

` 10,000

Pedal Assembly

` 20,000

10

Bellcrank

` 16,000

Total

` 2,00,000

CAR FABRICATION COST

Car Fabrication cost = Departmental Cost + Manufacturing Cost
= ` 9,68,930 + ` 2,00,000 = ` 11,68,930

TEAM CONTRIBUTION

S. No.

Contribution

Purpose

` 200x 24= ` 4,800

For initial brochures, reports, and flyers printing.

` 4,750x 24= ` 1,14,000

For FSAE Italy 2013 event registration.

` 4,200x 24= ` 1,00,800

For purchase of engine. A total sum of ` 1,00,000

was paid.

TOTAL

` 2,19,600/-

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 CAR SHIPPING, AND MEMBERS TRAVELLING AND

ACCOMODATION COST
REMARKS
1. Car

Flight
Ship

FRO
M
Ranchi
Varano De
Melegari, Italy

DESTINATION
Varano De
Melegari, Italy
Ranchi, India

b) Accommodation

` 1,48,000
` 4,48,000

TOTAL

2. Members
a) Travelling

COS
T
` 3,00,000

Train
Flight

Ranchi
New Delhi

New Delhi
Milan

Miscellaneous
cost in Italy
Flight

Milan

New Delhi

Train

New Delhi

Ranchi

Camping

500x 11= `5,500

21,000x 11=
`2,31,000
10,000x11=
`1,10,000
21,000x 11=
`2,31,000
500x 11= `5,500
4,500x11=
`49,500
` 6,32,500/-

TOTAL

SUMMARY
REMARKS
Car Fabrication Cost

AMOUNT
`11,68,930
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` 4,48,000
` 6,32,000

Car Shipping Cost

Travelling and Accommodation
TOTAL EXPENDITURE

Sponsorship amount
Team Contribution
TOTAL

` 22,48,930

` 13,68,001
` 2,19,600
` 15,87,601

*Travelling and accommodation cost was borne by the team

AMOUNT REQUIRED = Sponsorship collected + Team contribution for engine - Car
Fabrication Cost - Car shipping cost
= ` 13,68,001 + ` 1,00,000 - ` 11,68,930 - ` 4,48,000
= ` 1,48,929 (Deficit)

The car is currently in transit from Italy to India via sea route.
` 1,47,629 is the amount still to be paid to the Logistics company for the return of
the car.

RESULTS
Team SRIJAN secured 38th Position amongst the 55 teams from all over the world.
We also bagged 21st Position in cost analysis and our engineering design was rated as the 2 nd best
from a total of 8 teams that had participated from India. We were succeeded by Vellore Institute of
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Technology, Chennai, which were participating in this event for the 4 th consecutive year and were
preceded by IIT Kanpur who was also participating in this event for the first time.
The official result is attached with this report.

Official results can be referred on - http://www.ata.it/it/formulaata/view/20/formula-sae-italyformula-electric-italy-2013/content/272/results/

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THE PATH AHEAD

Soon after the event, detailed meetings were conducted on our performance on the event site and
the future course of action. It was discussed in great detail the mistakes that were made and how
should they be rectified. We also extolled ourselves over our achievement of having competed in
the International arena after a hiatus of 6 years.
Out of discussions, one thing was clearly evident that we need more time to raise funds,
satisfactorily, complete the manufacturing and test the car to our desired levels. So we are aiming
for an event that would give us more than a years time for achieving all the above milestones.
Secondly, in order to achieve podium finish like success, we need to have a team with extremely
sound technical knowledge. Hence, various decisions were taken as to how the team should be lead
from now on and how the members can develop and hone their technical knowledge and skill.
It was decided that the strength of the management team should be increased. It is done so as to
reduce the burden on rest of the members and at the same time have a proper team management.

Reaching at this level there is no looking back. The team is highly motivated and
wants to achieve more. The level of knowledge and
understanding of the event has increased over the years. The
team has now a strong technical support from its past members
(since 2k7 batch) placed in good industries who share their
practical knowledge regarding manufacturing and designing
with the team. With all the growing experience and support
from all corners and motivations, the team is determined to
participate at FSAE Australasia 2014 to be held in the month of December at
Melbourne.

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SPECIAL THANKS TO..

Srijan would like to thank few people without whose support; this project wouldnt be such a
success.

ALUMNI
Mr. S. N. Agarwal
Mr. S G Sureka
Mr. G K Gupta
Mr. Samir Kumar Sadhu
Mr. Madan Agarwal
Mr. Prakash Sacheti
Mr. D Hada
Mr. R P Jain
Mr. Abhinav Omar
Mr. Kaushlesh Maheshwari
Mr. Sidharth Malik
Mr. R. N. Vyas
Mr. Vishal Gupta (2k11 passout)
Mr. Vishal Gupta (an alumnus of Srijan)
Mr. Atul Prasad

1962 Batch

COLLEGE AUTHORITIES
Dr. P.K. Barhai Honorable Vice Chancellor, BIT Mesra
Mr. B.B.Pant - Dean External Relations & Coordination
Dr. Arbind Kumar Head of the Department, Mechanical Engg
Dr. B.K.Singh Head of the Department, Production Engg
Dr. Jeeoot Singh Faculty Advisor, Team Srijan
Dr. Vinay Sharma Dean Students Welfare
Mrs. Archana Mukherjee Dy. Finance Officer
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SPONSORS AND SUPPORTERS

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CONTACTS

Gaurav Sinha
Captain
8986682423
meetme.gauravsinha@gmail.com

Diwakar Harsh
Vice Captain
9939612494
divakar.harsh@gmail.com

Saket Kumar
Chief Engineer
9431104316
saketf2004@gmail.com
Team's website - teamsrijan.bitmesra.ac.in
Team's E-mail ID- teamsrijan@bitmesra.ac.in

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