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Methods and Construction

This project was designed in increments and sections. The majority was fabricated on campus with more parts being bought or sent to companies to get manufactured. The process has been broken up into sections. First the chassis which is the main support of the suspension was machined on campus with supplemental holes and billets on a waterjet with an outside retailer. Using Aluminum 6061, the material was band sawed then end milled to get the desired profile. Major issues were using the band saw and getting very precise and small radii. Slowly taking small cuts off each passthrough was conducted to achieve desired results. The surface finish after running the material against the band saw was awful. Milling and using gradual stages of sandpaper allowed for a smoother and more desired surface finish. After efficient machining, marking where mounting points and screws was crucial. Using layout dye and a sketcher, the desired measurements were marked out on the chassis plate. All locations requiring drilling were center punched with a hammer and punch. Using the desired allowable standard drill size, 3mm holes were produced. Issues regarding drilling were getting the proper mounting angle of the part. The parts varied in shapes so getting the device mounted in order to drill efficiently and safely was crucial. Additional supports followed this same process, like the T post support and trailing flatbed to attached components of the car. The final section of construction is the support struts, shocks, and control arms. These items were bought to ensure structural integrity and reliability. Allowing ample time for the purchased parts was the main issue. Shipping timelines and inventory in stock is something to be considered. The purchased parts were ordered early to try and deter this. The main suspension components, such as the trailing arms and control arms were bought to ensure proper fit and mounts.

Preliminary Drawing

This is a preliminary sketch of the R/C Mini Baja Car suspension. The chassis is a central piece of Aluminum and supports the main components of the car. The front of the suspension is designed to have a bash bar to withstand crashes and other debris to protect the integrity and components of the car. The Mini Baja Car is projected to have over sized coil-overs to create maximum amount of ground absorption when going off-road; creating a smoother ride for the car. Rear links are to be mounted from the back axle to the sub frame to create more support for the frame.

The first component manufactured was the T-post that will mount on the front of the chassis plate. The support mount is designed to attach the top of the struts to the post, which then connect to the control arms. The thickness of the material was a strong consideration due to the mount having to support variable amounts of loads when the device is in operation. The support mount was manufactured out of Aluminum 6061 and a thickness of .25" was chosen. The design was drawn in Solidworks and tolerances/measurements were described. Upon bringing the material to the machine shop, layout dye was spread on the aluminum sheet stock and ample amount of time was taken to allow for the dye to dry. Using an etcher to scribe the desired measurements and shape of the part was conducted. Then, the aluminum sheet stock was cut on the band saw until the desired shape was achieved. Deburring took place with a file to get rough edges eliminated. The part was then center punched in the specified locations, then loaded in the drill press vise. Using a 3mm drill bit, the part received four holes according to the Solidworks drawing. The manufactured part was taken to the layout box once again and dye remover was used to wipe off any blue dye left and to create a more attractive surface finish. 

Front Strut Support Post

Solidworks Drawing of Support Post

Attached below is the Solidworks drawing in regards to the support mount and critical locations/measurements. The drawing includes GD&T requirements. All manufacturing and call-outs reference drawing 20-0005.

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Front View of the Baja Car assembly.

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Rear mock-up view of suspension.

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Side view of rear strut mount and suspension.

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Isometric view of Baja Car.

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Drilling holes for shock mounting slots.

Detail view video of car mock-up.

Milling material on rear strut support mount.

Assembling rear suspension.

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First assembly with all components.

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Assembly drawing of RC Car.

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RC Car with shell on test day.

Video of RC car on testing day.

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