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    How To Build A BAJA ATV in 40 Steps

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    Manish O
    The method described in this presentation is just one way of pulling the build off, mostly based on what my team did. There is no doubt that there might be better ways. The purpose of this presentation was for the newbies to see how the various mechnicals come together, their relative proportions, sizes, positions, layouts, etc. Also, I shall carry out corrections and revisions from time to time, so that more information can be passed on effectively to successive BAJA aspirants. I hope that the readers will freely give comments, suggest corrections and pose queries. I'll be delighted to respond. THANKS!

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    How To Build A BAJA ATV in 40 Steps

    Uploaded by

    Manish O
    16K views57 pages
    The method described in this presentation is just one way of pulling the build off, mostly based on what my team did. There is no doubt that there might be better ways. The purpose of this presentation was for the newbies to see how the various mechnicals come together, their relative proportions, sizes, positions, layouts, etc. Also, I shall carry out corrections and revisions from time to time, so that more information can be passed on effectively to successive BAJA aspirants. I hope that the readers will freely give comments, suggest corrections and pose queries. I'll be delighted to respond. THANKS!

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    How to Build a BAJA ATV in 40 Steps

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    The method described in this presentation is just one way of pulling the build off, mostly based on what my team did. There is no doubt that there might be better ways. The purpose of this presentation was for the newbies to see how the various mechnicals come together, their relative proportions, sizes, positions, layouts, etc. Also, I shall carry out corrections and revisions from time to time, so that more information can be passed on effectively to successive BAJA aspirants. I hope that the readers will freely give comments, suggest corrections and pose queries. I'll be delighted to respond. THANKS!

    Copyright:

    Attribution Non-Commercial ShareAlike (BY-NC-SA)
    Download as PDF or read online from Scribd
    Download as pdf
    16K views57 pages

    How To Build A BAJA ATV in 40 Steps

    Uploaded by

    Manish O
    The method described in this presentation is just one way of pulling the build off, mostly based on what my team did. There is no doubt that there might be better ways. The purpose of this presentation was for the newbies to see how the various mechnicals come together, their relative proportions, sizes, positions, layouts, etc. Also, I shall carry out corrections and revisions from time to time, so that more information can be passed on effectively to successive BAJA aspirants. I hope that the readers will freely give comments, suggest corrections and pose queries. I'll be delighted to respond. THANKS!

    Copyright:

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    of 57

    Team STRATOS

    HOW TO BUILD A GOOD BAJA ATV


    (BUGGY) IN 40 STEPS
    1. SUCCESS AT BAJA= DEDICATED TEAM +
    SMART CAPTAIN + HELPFUL FACULTY ADVISOR
    2. DIVIDE THE TEAM, RESEARCH, BRAINSTORM,
    DISCUSS, DEBATE AND ARGUE
    3. MAKE A BASE PLAN AND THEN 3D CAD
    WIREFRAME
    4. BUILD PROTOTYPE OF SPACE FRAME. ESP.
    FOR FIRST TIMERS
    5. CAD MODELS AND ANALYSIS
    5A. PRELIMINARY AND FINAL MODELS
    6. OBTAIN A NICE AND TIDY WORKSHOP
    7. SET TABLE ACCURATELY AND MAKE
    MARKINGS
    8. START FROM THE BASE WITH NECESSARY
    MATERIALS
    9. FINALIZE AND SECURE BASE
    10. BUILD UPWARDS USING EFFECTIVE JIGS,
    MAINTAINING ACCURACY ALL THE WHILE.
     ALL CHANGES(IF ANY) MADE IN THE PHYSICAL MODEL MUST
    BE REFLECTED IN THE CAD MODEL
    11. ACCURATE EDGE PROFILES ARE CRUCIAL
    12. SPOT TALENTED WELDER(S), ENCOURAGE
    SUFFICIENT TRAINING AND START WELDING
    12A. GOOD WELDS ARE THE SECRET OF A GOOD
    CAR
    13. SCHEDULE WELL THROUGHOUT
    14. KEEP SPONSORS IN THE LOOP
    15. ENSURE FIT OF CRITICAL COMPONENTS
    16. COMPLETE FRAME
    16A. NOW BRING THE FRAME TO THE DESIRED
    RIDE HEIGHT. HELPS IN SUSPENSION BUILD
    17. WORK ON SUB-COMPONENTS MUST BE
    ATLEAST HALF WAY THROUGH
    18. ALSO ARRANGE FOR ALL ACCESSORIES
    19. START THE ASSEMBLY!
    20. FINISH CRITICAL COMPONENTS FIRST:
    A-FRONT SUSPENSION
    B-REAR SUSPENSION
    C-HUBS
    D-STEERING ASSEMBLY
    E- DRIVETRAIN
    F- BRAKE LINES, TIE RODS AND INNOVATIONS
    (IF ANY)
    21. INSTALL THE OTHER ESSENTIALS: SEAT,
    SAFETY KIT, ETC
    22. ELECTRICAL AND BODY PANELS ARE
    OPTIONAL AT THIS STAGE
    23. TIME FOR THAT FIRST EVER TEST DRIVE!!
    24. DISCUSS IMPROVEMENTS NECESSARY
    25. STRIP DOWN ALL THE PARTS FOR PAINT
    JOB. START BY SPRAYING RED OXIDE
    26. MAKE IMPROVEMENTS TO OTHER PARTS OF
    THE CAR SEPARATELY.
    27. APPLY PRIMER ON THE FRAME
    28. MIX PAINT WITH THINNER APPROPRIATELY
    AND TRY OUT
    29. NOW GIVE ATLEAST 2 COATS OF PAINT
    30. RE-ASSEMBLE THE CAR
    31. COMPLETE THE CAR TO THE MAXIMUM
    EXTENT: BODY PANELS, INNOVATIONS, ETC
    - COCKPIT
    Speedometer
    DIGITAL FUEL
    GAUGE - Hidden
    multimeter with
    custom fit LEDs!

    Lights

    DIGITAL GEAR
    INDICATOR

    Dual tone 4 terminal (IG-


    N123 I-Pattern
    dashboard Horn button BI-15-ST)
    Gear shift
    Ignition switch
    32. RUN FIELD TESTS FOR ATLEAST A MONTH
    (CRITICAL)
    33. MAKE YOUR COLLEGE COME TO LIFE AT 3AM
    34. HOPE THINGS FAIL HERE SO YOU CAN YOU
    CAN BE SAFER ON RACE DAY
    35. TEST MORE AT TOUGHER PLACES.

    Courtesy: Dirt Mania ATV dirt track, Kanakpura Road, Bengaluru


    36. HOPE MORE THINGS FAIL AT THE RIGHT
    TIME
    37. REPAIR AND TEST EVEN MORE.
    38. GO BACK TO GARAGE. CLEAN UP, TOUCH UP
    39. SHIP TO RACE TRACK
    40. KEEP TOOLS AND SPARES HANDY AND
    HOPE FOR THE BEST AT BAJA!!
    IF THINGS DON’T WORK OUT, DON’T BE TOO
    DISHEARTENED..
    ..YOU MIGHT STILL GET TO WIN ANOTHER DAY!
    MY PROFILE..
     I had the wonderful opportunity to be the captain of the much acclaimed 'Car#8-
    BOSCH Team Stratos, BIT', the team representing the institution at the BAJA
    SAEINDIA 2010 Competition, held at NATRAX, near Indore, M.P. This was the first
    time such an attempt was made in our college and were the only ones from
    Bangalore.

     Apart from being the skipper, I had a major role in the design phase of the all-terrain
    vehicle (ATV), using CATIA V5 extensively in part design, assembly, anthropometric
    analysis and use of in-built analysis package. I was involved in marketing as well,
    with the team getting major sponsorship backing from Bosch Ltd., among many
    other prominent companies. I’ve created the Team sponsorship brochures. Also have
    designed and implemented all the electrical systems in the car.

     My team consisted of 20 brilliant 4th, 3rd and 2nd year mechanical students. Our car
    was used to inaugurate the event as our team had won laurels for having the Best
    Design Report.

     We got our first podium finish at the BIAE ATV University Challenge when we finished
    at 2nd place in a 21Km endurance race.
    A FEW TIPS..
     You are most likely to have one shot at BAJA. So, keep reliability of all
    aspects largely within spec.

     Test, test and test more. Parts break when you least expect. This is
    that sort of terrain. I suggest atleast a month’s testing.

     Never EVER underestimate your opponents.

     Rule: OEM parts are ALWAYS more reliable than custom made ones.

     Respect the track. Its professionally crafted to reduce your car to


    shreds. This is where your worst case scenario is your most likely
    scenario.
    MY BEST WISHES TO ALL FUTURE BAJA
    ASPIRANTS!!

    -Manish O.
    THANK YOU!

    Do give suggestions and/or comments to make this more helpful.

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