Maverick Motorsports

2005 Car# 28
Ben Gruenzner Scott Rector
Nick Hanson Mike Schmitz
Aaron Pilger Jamie Schlachter
Dustin Kalhoff Ryan Schommer
Chris Kost Ryan Stebbins
Jason Kuenzli Paul Steevens
Justin Moe Mike Tichy

Faculty Advisors:
Dr. Bruce Jones and Mr. Gary Mead
 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
 Competition Events
Static Events
Technical Inspection No points
Cost and Manufacturing Analysis 100 points
Presentation 75 points
Design 150 points
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Total 325 points

Dynamic Events
Acceleration 75 points
Skid Pad 50 points
Autocross 150 points
Fuel Economy 50 points
Endurance 350 points
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Total 675 points
 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
 Decision Matrix

Cos
Wheel Decision Matrix Weight Performance t Reliability Brake Line Routing Total

Weighting 5 7 2 4 1

Keizer Mag 4 4 2 4 5 68

Keizer Aluminum 5 3 5 4 5 72

Sander Engineering D-Mount 2 2 2 5 0 48

Real Wheels 5 4 5 2 0 71
 Engine
Honda F4i 598cc 4-cylinder
engine
Naturally aspirated
Converted to run on E-85
ethanol
Performance Electronics
Engine Management System
 Intake Design
Single Plenum Design
19mm Restrictor
Heimholtz Calculations
 Exhaust Design
Only Scott Knows
3-31-05 FSAE Dyno run 3
 Drivetrain

6 speed, cockpit shifted manual transmission

Interchangeable drive
Torque proportioning differential
Direct drive aluminum spool
Custom RCV drive axles
Drive sprocket and chain driven
 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
 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
 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
 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
 Upright Designs
Aluminum
FEA Design
FEA Picture
 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
 Documentation
Design Report
Document Binder
 Vehicle Cost
Brakes System 804.46

Engine and Drivetrain 4985.44

Frame and Body 767.41

Instuments and Wiring 1147.83

Miscelaneous Fit and Finish 110.74

Steering System 525.74

Suspension and Shocks 2350.95

Wheels and Tires 1177.34

Total 11869.92
Any Questions?