FSAE Design Spec Sheet -- Note: SI units 2009

Competitors please replace the sample specification values in the table below with those appropriate for your vehicle and submit this to with your design report. This
information will be reviewed by the design judges and may be referred to during the design event.
--Please do not modify format of this sheet. Common formatting will help keep the judges happy!
--The sample values are fictional and should not be used as the baseline for your designs.

Car No. 123

School Super Mario State Technical University
Dimensions Front Rear
Overall Length, Width, Height 2338mm long, 1476mm wide, 1404mm high
Wheelbase 1676mm
Track Width 1410 mm 1475 mm
Weight with 68kg driver 121 kg 138 kg

Suspension Parameters Front Rear

Suspension Type Double unequal length A-Arm. Push Double unequal length A-Arm. Direct
rod actuated horizontally oriented acting spring and damper
spring and damper
Tire Size and Compound Type 20x6.5-13 R25A Hoosier 20x8-13 R25A Hoosier
Wheels (width, construction) 8 inch wide, 3 pc Al Rim, 20mm neg. 9 inch wide, 1 pc carbon, 34mm neg.
Center of Gravity Design Height offset offset
214 mm above ground (confirmed with testing)
Suspension design travel 32mm jounce/ 29 mm rebound 48mm jounce/ 36 mm rebound
Wheel rate (chassis to wheel center) 38 N/mm 48 N/mm
Roll rate (chassis to wheel center) 3.14 degrees per g
Sprung mass natural frequency 1.53 Hz 1.62 Hz
Jounce Damping 42% of critical damping at X mm/sec 38 % of critical damping at X mm/sec
Rebound Damping 72% of critical damping at X mm/sec 68 % of critical damping at X mm/sec
Motion ratio / type 0.91 / linear 0.82 / progressive rate
Camber coefficient in bump (deg / m) 19.3 deg / m 32.5 deg / m
Camber coefficient in roll (deg / deg) 2.62 deg / deg 2.62 deg /deg
Static Toe -0.2 deg toe (toe out) 0.3 deg toe in
Static camber and adjustment method -1.5 deg, adj. via shim plates on A-arm -0.5 deg, adj. via inboard rod ends
Front Caster and adjustment method 13 degrees non-adjustable
Front Kingpin Axis 2 degrees non-adjustable
Kingpin offset and trail 6mm offset, 3mm trail
Static Akermann and adjustment 110% non-adjustable
method
Anti dive / Anti Squat 0 -30%
Roll center position static 34mm above ground 12mm above ground
Roll center position at 1g lateral acc 30mm above ground, 154mm toward 5mm above ground, 280 mm toward
unladen side laden side
Steer location, Gear ratio, Steer Arm Front steer, 25mm c-factor, 62mm steer arm
Length
Brake System / Hub & Axle Front Rear
Rotors Floating, Cast Iron, hub mounted, Outboard, 260 mm dia x 10mm Carbon
205mm dia. vented ceramic
Master Cylinder Student Built 22mm bore front / 19mm bore rear with driver adjustable bias bar
Calipers 48mm dia., Opposing piston, fixed mtg Dual piston,25mm dia., floating
Hub Bearings Tapered roller bearings. Separate Single 5205 dbl row ang contact
spring loaded rubber lip seal bearing with integral seal
Upright Assembly CNC 7075-Al, integral caliper mount Weldment, 4130 sheet, heat treated,
shot peened
Axle type, size, and material Fixed spindle, 28mm dia, 4130 steel Rotating axle, 52mm ODx 2.5mm wall,
normalized 4340 steel, RC 40

Ergonomics
Driver Size Adjustments Fixed seat and steering wheel. Pedals adjust fore and aft 75mm from center
Seat (materials, padding) position
Wet lay-up carbon, padded lumber and knee protection, 80mm foam head
Driver Visibility (angle of side view, support
210 degree side visibility, 60 x 100mm side mirrors rigidly mounted to nose
mirrors?)
Shift Actuator (type, location) Manually actuated lever/ linkage, right side cockpit mount
Clutch Actuator (type, location) Foot pedal, cable actuated
Instrumentation Dash mounted temp/oil gauge, 5 LED tach/shift light

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Frame
Frame Construction Frt and rear Tubular space frame / AL Monocoque mid section
Material 1020 and 4130 steel round tubing .5" to 1.125" dia / 2024-t3 .031" thk Al sheet
Joining method and material Fusion welding ER70-S6 filler / 2 part room temp cure epoxy
Targets (Torsional Stiffness or other) 6000 N-m / deg
Torsional stiffness and validation method6500 N-m/deg CAE beam model, 5700 N-m/deg physical test
Bare frame weight with brackets and paint32 kg
Crush zone material closed cell PVC, aramid composite casing
Crush zone length 150mm
Crush zone energy capacity FEA -- 8200 Joules, physical test -- 9680 Joules

Powertrain
Manufacture / Model Yamagucci ZAZ-6 4 cylinder, Cyl 3 designed to miss-fire every 8th revolution
Bore / Stroke / Cylinders / Displacement 58mm bore / 57mm stroke / 3.75 cylinder / 601 cc
Compression ratio 13.3:1
Induction Rotary screw supercharger and Garret T03 turbocharger
Throttle Body / Mechanism 45mm, butter-ball throttle actuation
Fuel Type E-85 ethanol
Max Power design RPM 13000
Max Torque design RPM 12000
Min RPM for 80% max torque 8000
Fuel System (manf'r, and type) Student des/built ,fuel injection, sequential
Fuel System Sensors (used in fuel mapping)
Air Temp, Coolant Temp, Throttle Pos, Crank Pos,…….
Fuel Pressure 4.5 bar
Injector location 85 mm before and pointing toward intake valve
Intake Plenum volume and runner length(s)1346 cc
Exhaust header design 4-2-1 equal length (+/- 20mm), 50mm collector
Effective Exhaust runner length 450mm
Ignition System Student des/built ,dual coils, lost spark system
Ignition Timing 3-D map, RPM and Throttle position, 23 deg BTDC max advance
Oiling System (wet/dry sump, mods) belt driven dry sump, 2 scavenge / 1 pressure pump
Coolant System and Radiator location Twin side pod mounted radiators with thermostatic controlled electric fans
Fuel Tank Location, Type Floor mounted between firewall and engine, aluminum tank w/fuel bladder
Muffler Single glass pack muffler, 2.5 liter volume
Other significant engine modifications Height of engine reduced by 60mm with removal of oil sump volume

Drivetrain
Drive Type 30mm x 10mm wooden cogged belt
Differential Type clutch pack limited slip, 100Nm preload, 1.4 bias ratio
Final Drive Ratio 2.52
Vehicle Speed @ max power (design) rpm
1st gear 18 mph
2nd gear 35 mph
3rd gear 54 mph
4th gear 72 mph
5th gear 91 mph
6th gear removed from trans
Half shaft size and material 30mm OD solid 8620 steel case hardened to Rc 60 1.3mm deep,Rc 28 core
Joint type hardness
TRE mini Tripod- left, Honda Scammer ATV- right

Aerodynamics (if applicable)

Front Wing (lift/drag coef., material, weight)
N/A
Rear Wing (lift/drag coef., material, weight)
N/A
Undertray (downforce/speed) 50N at 40mph (per analysis), center of pressure 60mm aft of vehicle CG
Wing mounting N/A

Optional Information
Body Work? 1 piece carbon latex body, 3.6 kg complete w/ bodywork
Special Bit A? "Mega-Horn" deer siren
Special Bit B? Chrome Whistle Tip- exhaust tips

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