Complete Porfolio

Davon Mukhar
Engineering
Portfolio

MAE 195: Racecar Design and Manufacturing
Name: Davon Mukhar
Description: The frame and paneling of the
aluminum chassis was already complete when I
came into this project however it was not rigid
enough. To increase strength and rigidity for
better handling and maneuvering of the vehicle,
stringers began to be installed on the walls and
the floor of the chassis. These stringers needed
to be measure and filed down to fit along the
aluminum paneling sheets. Once fit to size
holes were drilled in the stringers and panels
and the stringers were installed with rivets.
More stringers were used in the area of the
chassis where force will be concentrated, such
as the suspension mounting area and the driver
compartment.
Documents:
Photographs
Assisted by:
Kevin Sale
Tyler
Chris Kent
1
Week 1 – Chassis Strengthening with
Stringers

Name: Davon Mukhar
Description: This week we completed
installing the streamer by drilling and riveting
them on to the aluminum chassis. This was a
long a tedious process however it will
significantly aid the driver with maneuvering as
the stringers will increase the rigidity of the
finished vehicle.
As a new and younger member of
Racecar I began learning how to arc weld iron.
At this point I am perfecting creating a bead
and only tinkering with scrap pipe and
attempting to weld them to iron plates. As the
quarter goes on I plan to learn more and perfect
my welding techniques.
Documents:
Photographs
Assisted by:
Jose Ortis
Chris Kent
Tyler
Kevin
1
Week 2 – Learning to Arc Weld and Stringer
Completion

Name: Davon Mukhar
Description: The chassis riveting is completed
and all the stringers are attached with rivets.
The next step is creating the suspension arms to
be attached to the body. The steel pipes needed
to be profiled so that they will fit together
respective with their orientation and then
welded together. I completed the profiling for
on set of suspension arms which consisted of
six steel pipes. In addition to this task I also
progressed in learning how to be come an
effective and elegant welder, I practiced
welding pipes to each other as well as to flat
surfaces. Lastly this week I was given the task
to create brackets to support the motor
controllers for Zeta. These brackets needed to
engineered from scratch so that the controllers’
panel can sit two inches above the areas they
will be mounted on the chassis .
Documents:
Photographs
Assisted by:
Chris Kent
1
Week 3 – Welding, Profiling, and Making
Brackets

Name: Davon Mukhar
Description: This week I finished the control
mount for Zeta and drilled the hole for
mounting. This will mount the controllers that
will be connected to the electric motor for the
drive train. Now being both painted and clear
coated Zeta is ready to be assembled. My next
task is to design a way to mount and connect
steering potentiometer to the car’s computer.
This devices delivers information regarding the
turning of the wheels that will determine which
rear wheel will receive more power. This
increases control for the driver when turning
and cornering at high speeds. This device need
to be mounted to a fixed part of the steering
rack that will slide as the driver turns the
wheels. This will be tricky as there is very little
space to mount this delicate electronic
instrument.
Documents:
Photographs
Drawing
1
Week 4 – Control Mounts and Steering
Control

Name: Davon Mukhar
Description:
This week Zeta was being assembled. The
chassis was completed and the was painted with
a blue paint and clear coated for protection.
Now the car can be assembled with all the
parts needed for the car to operate. I installed
the steering rack which allowed me to then
determine the design of the mount fort the
steering potentiometer. A steering
potentiometer determine the degree to which
the front wheels turned and then powers the
rear wheels accordingly for maximum
handling. Another task that I worked on this
week was creating the hangers that would
mount the break calipers for the front wheels.
These uprights needed to be created from
scratch and made of steel to properly support
the break calipers.
Documents:
Photographs
Assisted by:
Chris Kent
Katie Leong
1
Week 5 – Install Steering Rack /
Potentiometer

Name: Davon Mukhar
Description:
This week Zeta was being assembled. The
chassis was completed and the was painted with
a blue paint and clear coated for protection.
Part of the assembly for the car was running the
brake lines and installing the calipers. The lines
need to be flared and then attached to the male
and female components in the caliper, pedals,
or connectors. The car has four brakes, all
hydraulic disc inside the wheel assemblies. We
used a metal brake line through out the car and
the rear axel and a soft line for the front wheels
that steer.
Documents:
Photographs
Assisted by:
Sharango Kundu
1
Week 6 – Brake System Assembly

Name: Davon Mukhar
Description: This week I had to determine an
appropriate design for a chain guard. The chain
guard is required by Formula SAE as a safety
feature on all chain or belt drive train vehicles.
The guard for a chain must wrap the bottom
point of both the motor cog and axle cog, there
is also a certain thickness the steel must be. The
challenges with the initial design will be
bending thick steel into a perfect arc as well as
mounting the chain guard around the motors
and motor controls that are already mounted in
space. Another challenge was how to mount
and whether or not we would like to put more
holes into the rear part of the chassis since it
has already many part already mounted to it.
Documents:
Photographs
1
Week 7 Chain Guard

Name: Davon Mukhar
Description: Now that I have developed a
design for a chain guard I needed to
manufacture it. I had to cut a piece of steel that
was approximately three feet long, four inches
wide, and quarter inch thing. To cut this I used
a table saw and after it was cut I buffed the
edges with an electric buffing wheel. Now that
the steel was ready to be bent I had to
determine how and how far to bend it. I
determined the radius I needed and decided it
was comparable to the larger wheel on the an
English wheel. The English wheel wasn’t
necessarily designed to bend metal but the
larger and small wheel were the perfect radius
to bend my steel around for the axle and motor
cogs. To mount the guard the controls were
removed and the guard was cut in half and then
welded to tabs that were drilled into the chassis.
Documents:
Photographs
1
Week 8 Chain Guard Manufacturing

Name: Davon Mukhar
Description: After much contemplation and
discussion it was determined that Zeta was
going to get a slide potentiometer because there
was not enough time to order a custom radial
potentiometer to meet our specifications. We
needed to determine how to mount the
potentiometer to the car as well as how to
connected the slider to the steering rack. The
full travel of the potentiometer must be able to
be moved by the steering so that the controls
receive accurate information about what the car
is experiencing when its turning. We designed a
systems of steel bars to connect the
potentiometer in an accessible place and
connect to the steering.
Documents:
Photographs
1
Week 9 Steering Potentiometer
Assisted by:
Chris Kent
Jose Ortiz

Name: Davon Mukhar
Description: This was the last week of race
car. As a second year in school and my first
quarter on the team I can with out a doubt say
that I learned a large amount of valuable
information about engineering. This last week
I worked a little less than usual because the
tasks that needed to be complete would not
have suited my experience, however there was
still some I could do. The aluminum frame,
Gamma Prime chassis needed some steel
suspension mounts made. I drew the outline
and then cut out the middle of the blocks and
then used the grinder to shape them correctly.
Documents:
Photographs
Assisted by:
Mason Sattes
1
Week 10 Gamma Prime Suspension Mounts

Name: Davon Mukhar
Description: Part of the design for the Baja
car’s drive train will be gearing the engine with
a transmission. For this we have the option
between a CVT (continuously variable
transmission), or a geared transmission from a
motorcycle or ATV. The factors that play in to
determining which one we will use will be the
weight of the components and the
functionality. Ideally we would like to have a
reverse drive gearing but this does not exist on
most accessible CVTs nor motorcycle
transmissions (which are alone heavier than
desired) and mainly found on larger hunting
ATVs. In addition to transmission drive train
work, this week I was also working practice
Solid Works. As an Aerospace major Solid
Works is not in my required curriculum so I
have to independently learn how to use this
software.
Documents:
Photographs
Assisted by: ----
13
Week 1 – Transmission and Solid Works

Name: Davon Mukhar
Description: Over the weekend the Beta car
that is being worked on by my team for the
energy invitational, hit a pole and bent the left
A-arm on the front wheel; thus a new one had
to be made. We decided that the arm did not
have to be bent like originally so we decided to
make it triangular instead to avoid having to
bend it. Also this week we decided that a FNR
(forward neutral reverse) CVT would be the
best option for the Baja vehicle. We decided
that the CVT will: prevent stalling, and thus
restarting the vehicle will not be an issue. As
well as being easier to operate and install, be
relatively lighter, and have a reverse driving
mode which is necessary incase we need to
rock the vehicle to get it unstuck in
competition.
Documents:
Photographs
Assisted by:
Max Venaas
Week 2 – A-Arm Replacement and CVT

Name: Davon Mukhar
Description: We decided to experiment with
our TIG welding abilities and try it out on the
newly designed A-Arm for Beta. After this we
installed it on the chassis and set the toe of
the upright. Beta was taking to a track day this
weekend to due further adjustments on the
suspension and wheel angle to prepare it for
the energy invitational. In addition after Zeta’s
crash it needed to sanded and re-painted. I
sanded it to take the pain and finish off before
repairs and repainting.
Documents:
Photographs
Assisted by:
Max Venaas
15
Week 3 – Install A-Arm for Beta

Name: Davon Mukhar
Description: This first step analyzing the
strength of a chassis design after completing
an FEA will be to create a half scale model
that can be further analyzed. This half scale
model will be created with the same mild steel
that the full scale will be built however the
tubing wall thickness will be thinner and the
diameter will half of the full scale. The
requirement for tube diameter under the Mini
Baja specifications is 1in. and we are going to
conform with this minimum spec. The
minimum wall thickness required is .035in.
however we are planning to use .06in. for
safety and strength. The roll hoop and cage
however, must be a thicker walled tube of
.12in. All tubing material are being purchase
and priced from Industrial Metal Supply Co. in
Irvine.
Documents:
Photographs
Mini Baja Rules
Assisted by:
Max Venaas 16
Week 4 – Half Scale Chassis Material

Name: Davon Mukhar
Description: This week in race a car the Baja,
Green Team, was preparing Beta for the
Energy Invitational on May 10th. The first
concern was Beta’s tires, they needed to rotate
and flipped on the wheels. This will prevent
the threads from being exposed and prevent a
blowout. In addition the brake light as well as
the tachometer for the motor needed to be re-
wired. The brake light is a requirement for all
vehicles entering the Energy Invitational . The
rpm reader will allow us to better manage the
fuel consumption as we can determine how
much energy the engine is consuming.
Documents:
Photographs
Assisted by:
Baja Race Car Team
17
Week 5 – Energy Invitational Pre-Lim

Name: Davon Mukhar
Description: This week was the Energy
Invitational. This event is hosted by UCI and it
is a challenge of efficiency. Each team is given
a dollar’s equivalence worth of fuel to see who
can go the furthest while managing time. My
team was racing the UCI car, Beta. To improve
Beta’s performance I decided to create a nose
cone that will make the chassis more
streamlined thus increasing aerodynamics and
efficiency, without this measure Beta would
not stand much of chance compared to
electric vehicles. After the competition we
realized while the modifications were
beneficial, because we did not precisely know
how Beta was going to improve we were not
able to make the most precise energy
calculations to maximize our points. As a result
Beta placed second, however we learned a lot
on managing a race team.
Documents:
Photographs
Assisted by:
Max Venaas
Beta Race Car Team
18
Week 6 – Energy Invitational

Name: Davon Mukhar
Description: For SAE Baja the power plant for
the vehicle are pre-determined and actually
given to us by the SAE competition. The
motors are not allowed to physically modified
but some additions are acceptable. With this
we have to choose a transmission very
carefully so that it will work the best possible
with the engine. In addition to having a
transmission that is well suited for the engine
it must have certain functions for the events in
the competitions. It must be light and compact
as well as having a forward, neutral and
reverse drive modes. Having reverse will allow
us to get unstuck, without it we could be
disqualified if we get stuck during an event.
One thing that has to be assessed is whether
or not we are going to need high and low drive
modes which can change the amount of
torque delivered to the wheels.
Documents:
Photographs
19
Week 7 – Polaris CVT Specifications

Name: Davon Mukhar
Description: This week we created goals and
deadlines for the mini baja car we are
designing. Our goal is to attempt to complete
at least one half scale model so that we can
analyze the possible characteristics of a full
scale chassis. In addition, this week we
completed a FEA on the chassis in SolidWorks
to compare the structural strength of each
design. I am still determining and attempting
to obtain specs and a proper model
transmission from Polaris. Most of the
information we need is proprietary and is
making this difficult. Lastly this week we
prepared Beta for storage and moved it into
the cargo container for the summer.
Documents:
Photographs
Assisted By
Max Venaas
20
Week 8 –Beta Storage and Baja Drivetrain

Name: Davon Mukhar
Description: The final goal of the Baja team
this quarter is to create a full model of the baja
car to be manufactured in the fall. This
requires parts to be designed or found online
and pieced together. I am still trying to find a
proper model and specification for a Polaris
FNR CVT. This maybe replaced in the initial
model with the currently existing Comet CVT
from the Beta car, which may be also taken
apart for testing and analysis before
fabrication on the new vehicle is started. On a
side note the FEA completed on our chassis
model has shown an undesirable result as our
model seems to be failing at certain points. At
this point we think it is because of human
error when setting up the FEA rather than a
bad design, but we cannot be sure either way.
Documents:
Photographs
Assisted by:
Matt Miller
Max Venaas
21
Week 9 – Baja Model

Name: Davon Mukhar
Description: In this final week the goal is to
complete piecing together the Baja car model
in SolidWorks. We are presenting a poster at
the spring design review and really would like
to have a final model to go along with the
poster. Most of the parts have been designed
or found in the archives and the last major
step is to set the suspension and steering
geometries on the vehicle. We are planning to
use an on-board rocker system. This will allow
to keep the shocks within the chassis rather
that having them fully exposed on the sides.
This can result in a smaller travel required of
each individual shock which will cut down on
weight and could lower the center of gravity
for the vehicle.
Documents:
Photographs
Assisted by:
Matt Miller
Max Venaas
22
Week 10 – Finish SolidWorks Model

Week 1 – Cleaning Engine Lab and Driveline
Name: Davon Mukhar
Description: This quarter I have been
assigned as one of the team leads on the Baja
car. My sub-system lead will be for drive line
and driver interface as well and Max will have
chassis and suspension. To begin the year we
needed to clean the engine lab and
reorganize it to allow is to be more efficient
workers rather than wasting time hunting for
equipment. I also had to learn about driveline
and driver interface. Last quarter we left off
and decided to use a CVT with ideally a high,
low, reverse, and neutral driving mode.
Obtaining this will be more tricky because
many ohv vendors make their own. In
addition to obtaining components we also
need to determnine what types we need, for
example a solid rear drive axle or differential.
Documents: Photos
Assisted by: Max Venaas
24

Week 2 – Drivetrain Parts
Name: Davon Mukhar
Description: The Baja car will most likely have
a wish bone type axle in the rear instead of a
solid axle. This means we will need a CV joint
to attached to half shafts. The main problem
with a CV is that most common maximum
angle that can be achieved is 20 degrees
which may be tricky to use while trying to
achieve 12 inches of suspension travel.
However after researching other baja groups
and researching manufacturers I have founds
a cv joint that will allow 40 degrees of
movement which may allow us to get 12
inches of suspension travel.
Documents: Photos (see attached), Docs on
Drive
Assisted by: Baja XV Drivetrain Team
25

Week 3 – Vehicle Weight and Track Day
Name: Davon Mukhar
Description: This week the driver interface
team, drive train team and I determined the
weight on certain components of the vehicle.
Estimating an approximate weight will allow
us to determine the theoretical center of
gravity and thus design the suspension
geometry more accurately. Also this week
was the Baja XV team’s first track day. I design
a 1447 ft course that included hair pins,
straight-aways, and slalomed curves for the
purpose of driver development. We used this
day to show the team what race day would
be like and what duties are conducted by the
host race team, such as timing, and flag work.
Documents: Photos, Driver Times
Assisted by: Max Venaas and Baja XV Team

Week 4 – Steering Geometry and CVT Torque
Name: Davon Mukhar
Description: This week the Baja XV Team has
nearly finalized a suspension geometry that
will allow fabrication of half scale chassis
models to be fabricated. With this a steering
geometry can be designed that will allow the
steering linkages to be low weight and in a
geometry that is compact and out of the way
of the driver and other components.
Documents: Photos (see attached)
Assisted by: Zeta Battery Box Team, Baja XV
Driveline Team
27

Week 5 – Half Scale Model and Steering
Name: Davon Mukhar
Description: This week manufacturing of the
half scale model began. Our goal is that we
will have two complete half scale models that
we can do testing on this fallowing week. In
addition, we are going to fabricate a half scale
steering set geometry that we can analyze to
compare different set ups.
For the driveline team we have decided
that we are going to fabricate a differential in
house. This differential will gear down in a 4:1
ratio our transmission output to our wheels
in addition to having a reverse gear train that
can be selected by the driver when the
vehicle is stopped.
Documents: Photos (differential:
hypothetical set up)
Assisted by: Baja XV Human Interface Team,
Jeff Beasley

Week 6 – Half Scale and Steering
Name: Davon Mukhar
Description: This week in the Baja XV team
we were beginning the fabrication of our
second chassis design half scale. This half
scale will most likely be our final design
because it is rules compliant where our first
half scale design would infract on the
clearance between chassis and driver’s head
rule. In addition to the half scale chassis,
working with JJ, we are designing a proper
steering geometry that will limit the amount
of bump steer. The problem we are having
though is the clearance between the tie rods
and the a-arms. We will be able to properly
design this geometry as well as the design of
the uprights when the suspension team has
finalized their suspension geometry.
Documents: Photos, Chassis #2 Drawing
Assisted by: Baja XV Chassis Team, JJ
Javellana

Week 7 – Second Half Scale Fabrication
Name: Davon Mukhar
Description: The goal for this week is to
complete the second half scale model, which
unlike the first design is rules compliant.
Through the process of fabricating this model
we will be able to develop a technique of
fabrication that we will apply when building
the full scale chassis, our goal to have
completed by the end of the quarter. When
the half scale is complete we can do further
structural analysis as well as part geometry,
set up half scale assemblies that can also be
studied dynamically such as steering and
suspension.
Documents: Photos
Assisted by: Chassis Team

Week 8 – Finish Half Scale Begin Full Chassis
Name: Davon Mukhar
Description: This week we have finished the
half scale model and have decided to begin
fabrication of our full scale chassis. The full
scale will be fabricated with the use of
wooden jigs that will insure that the
geometry is correct during welding. We have
decided to use our beta chassis design as this
design is rules compliant and caters to the
goals we have for our vehicle.
Documents: Photos
Assisted by: Baja XV Chassis Team

Week 9 – Fabricate Full Scale
Name: Davon Mukhar
Description: This week we are preparing for
the Fall 2014 Design Review. Our goal as a
team is to have a completed chassis that we
can display. The fabrication process is going
relatively smoothly because of the amount of
people and delegating tasks accordingly so
that every one is contributing to the goal at
hand. We have all the members cut to length
and the remaining members only need to be
profiled and welded to the chassis which we
plan to have done by Friday.
Documents: Photos (see attached)
Assisted by: Beta XV Team, Curtis

Week 10 – Finishing Chassis and Design Review
Name: Davon Mukhar
Description: This week we were putting the
final touches on full scale before the fall
design review. We inserted pvc members
where we wanted to display the possibility of
adding other members to chassis but had not
yet. We hope to being ordering the
components for drivetrain and user interface
gradually before the next quarter and early
winter quarter 2015.
Documents: Photos (Calculation
Assisted by: Baja XV Team, Max Venaas

Week 1 – Complete Chassis
Name: Davon Mukhar
Description: The first task of the quarter for
the Baja XV was to complete the chassis. With
an updated FEA on modified chassis with
some members removed, we have
determined that the chassis is of a
comparable strength a no significant change
to chassis’ integrity was affected. With this
we completed the full scale chassis. I have
begun a preliminary design for a steering
system by taking calculations determined
between JJ Javellana, who is not longer in the
course, and myself from last quarter. At this
point the suspension team will complete the
suspension design and mounting tabs will be
attached to the chassis
Documents: Photos
Assisted by: Max Venaa, Nick Borrelli, Ryan
Roach

Week 2 – Steering Design and Track Day
Name: Davon Mukhar
Description: This week in race car I began
initial design of the steering system. We want
a steering setup that will allow for the most
maneuverability as well as diminish the
amount of bump steer occurrence. This can
be accomplished with a simple design,
however the final design we rely on the
orientation of the suspension, uprights, and A
– arms. In addition this week I built a new
ramp for the container where we store some
vehicles that is 17 inches off of the ground.
Documents: Photos, steering design
calculations
Assisted by: Kyle Taggart and Baja XV Team

Week 3 – Steering and Breaking Calculations
Name: Davon Mukhar
Description: To determine an appropriate
point to begin analyzing what kind of breaks,
steering wheel, and rack and pinion we need,
we analyzed our old Baja car Beta. We
determined that the Beta is 1.25 turn lock to
lock and therefore our initial goal to have our
steering 1.5 lock to lock will allow for more
precision, and being that we have a larger
cockpit, it will allow for more space to turn
the wheel. In addition we made calculation to
determine the breaking force on the Beta car.
We determined that with the rear breaks
disconnected that we could stop in 20 feet at
a rate of 20mph.
Documents: Break Testing Data, Photos
Assisted by: Jeff Beasley, Patrick Kim

Week 4 – Steering and Seat Design
Name: Davon Mukhar
Description: This week in race car
engineering I began modeling the steering
design as well as seat ergonomics in Solid
Works. We have determined that an
additional member will be needed to be
attacked to the chassis so that the seat and
seat belts can be properly mounted. The
steering rack will be placed in the front
control box and aligned in line with edges of
the box to reduce bump steer.
Documents: Photos, SolidWorkds Models
Assisted by: Patrick Kim, Frank Cai

Week 5 – Steering Column Design and Uprights
Name: Davon Mukhar
Description: This week in racecar engineering
we ordered the rack and pinion assembly for
our steering as well as a steering wheel and
seat. The rack will give us 1.5 turns lock to
lock and we wanted a felt textured 10 inch
steering while with 1 inch diameter around
for suitable grip in wet or muddy conditions.
In addition preliminary design has begun on
the steering column. We would like a steering
column that is out of the way of the drivers
feet so that the driver has the option of using
one foot or both to drive with. If the column
ran directly between the legs this would not
be possible.
Documents: CAD Files
Assisted by: Patrick Kim, Frank Cai

Week 6 – Finalize Designs and Gantt Chart
Name: Davon Mukhar
Description: This week we created our team
Gantt chart that we will go off for the rest of
the quarter and next quarter. We determined
the hard deadlines for design where we
would stop designing and beginning
fabricating what we have. As a first year team
we need to just get a car rolling so it can be
analyzed. Any unfinished design can be goals
for the next generation vehicle.
Documents: Gant Chary, Photos
Assisted by: Max Venaas and Baja XV Team

Week 7 – Prep Engine Lab for Assembly
Name: Davon Mukhar
Description: Up to this point in the project
most of our work has been in the weld lab,
but with the chassis complete, we have began
ordering parts and began to prepare for
assembly of the vehicle. As a first generation
prototype are goal is to obtain most of our
part off of the shelf so we can at least get a
car running. This will allow future iterations of
an off road Baja car to improve upon our
initial designs. In addition we determined an
angle of 25 degrees from the normal for out
seat angle which will allow taller drivers to fit
in the vehicle.
Documents: Photos, Rules’ Diagram
Assisted by: Frank Cai, Max Venaas

Week 8 – Pedal Assembly and Light Sensor
Name: Davon Mukhar
Description: With an appropriate master
cylinder chosen that would deliver an
adequate amount of pressure a pedal
assembly needed to designed. There are
many off the shelf options for pedal
assemblies. The next step, will be to
determine a strength needed for a pivot point
for the pedal. A person can deliver between
200lb – 300lb of brake pedal force, however
with an adrenaline rush this can double.
Therefore a moment point that can support a
500lb – 600lb shear force about a moment
arm of 10in. – 12in. In addition a brake light
sensor must be attached to each of the two
brake circuit systems to activate a brake light
for the vehicle.
Documents: Photos, Drawing

Week 9 – Steering Mounting and Column
Name: Davon Mukhar
Description: One of the design goals was to
have an adjustable steering mount that will
allow the steering wheel to adjust to shorter
and taller drivers. The adjustable column will
allow a variety of angles tilting the steering
wheel closer or further from the driver. In
addition, preliminary design was determined
for the steering wheel mounting member,
that will allow for more clearance for the
driver’s legs when they enter and exit the
vehicle.
Documents: Photos, Model

Week 10 – Mounting Points and Design Review
Name: Davon Mukhar
Description: This week we were expecting to
receive parts that have been ordered
throughout the quarter. This would allow us
to have a rolling vehicle at the design review.
However, because of shipping logistics were
not able to achieve this. Instead we were able
to mount tabs and install body panels and
engine mounting points. We also mounted
suspension tab and A-arms and steering rack
mounting points. By the first week of next
quarter we are expecting to have a fully
rolling vehicle with another week lead time to
get it to initial shakedown.
Documents: Photos
Assisted by: Baja XV Team

Week 1 – Sourcing Parts and Seat Tabs
Name: Davon Mukhar
Description: The initial goal for this quarter is
to make sure that all the parts required get
ordered by the second week of school to
ensure that we receive them with enough
time to assembly the vehicle. The
competition is week nine and our goal is to
have a running car week six so we have an
adequate amount of time for testing, tuning,
and driver development. Most parts for user
face have been sourced. The seat tabs have
been mounted in the appropriate positions
that comply with the rules.
Documents: Photos
Assisted by: Max Venaas

Week 2 – Steering Column and Tie Rods
Name: Davon Mukhar
Description: The final design for the steering
set up has been determined. We are going to
purchase an adjustable tilt steering column as
well as fabricate a telescopic steering shaft.
This will allot for adjustments to fit drivers
comfortably. Our developed telescopic set up
will include multiple length options where the
shaft can be pinned and clamped for a static
shaft feel, and adjusted as necessary. In
addition to limit the amount of bump steer a
tie rod length of 17 inches has been
determined. These will meet the steering rack
that has been extended 3.6 inches on either
side with a clevis so that the pivot point will
align with the A-arm pivot point. Doing this
will cause the A-arms and steering tie rods to
have the same rate of change of angle when
the suspension cycles.
Assisted by: Vanessa Zin

Week 3 – Mounting Steering Rack
Name: Davon Mukhar
Description: This week I determined the
angle the steering tie rods would experience
as the suspension cycles from maximum
compression to maximum extension. As a
result I needed a super swivel or high angle
ball joint rod end for the tie rods. After the
angle was determined, I determined a
location where interference between the
steering at full lock and the A-arms would not
occur. We mounted the steering rack using
four mounting tabs. Using four mounting tabs
will give the strength and rigidity required for
the steering forces and at an angle such that
a U-joint would effectively link the steering
shaft to the rack.
Documents: Photos, Calculations
Assisted by: Ronny Gutierrez, Frank Cai

Week 4 – Steering/Vehicle Assembly
Name: Davon Mukhar
Description: The steering system has been
design and with components received we
began fabrication. We used a DOM steel
lower shaft for strength and rigidity for the
component directly mounted to spline pin.
For the upper shaft we used ¼ inch thick
aluminum alloy which is much lighter than
steel but will also provide the stiffness
required from driver steering input. The goal
for the entire vehicle will to have it running
by the end of this week.
Documents: Photos
Assisted by: Venessa Zin

Week 5 – Rear End Fabrication
Name: Davon Mukhar
Description: The final design for out chain
driven rear end was finalized. Components
that would link our half shafts to a solid rear
axle where the chain sprocket and brake rotor
will be mounted need to be fabricated. I
machined the sleeves that will attach the half
shaft splines to the solid center axle.
Documents: Photos

Week 6 – Human Interface Components
Name: Davon Mukhar
Description: Our new goal for the vehicle to
have every mounting welded and in operating
condition by the beginning of week 8 so that
we can test for a week and tune suspension. I
had to determine final human interface
components. In addition the mounting plate
for the engine and FNR gear box were
completed and mounting point were
developed for those as well.
Documents: Photos

Week 7 – Redo Steering Mount Location
Name: Davon Mukhar
Description: After the steering mount points
were tacked into place we decided to adjust
the position of the mounts that changed the
angle of the steering shaft. This allowed for a
better driver ergonomics when driving the
vehicle.
Documents:
Photos
Assisted by:
Baja XV Team

Week 8 – Vehicle Testing
Name: Davon Mukhar
Description: With the vehicle drive train
assembled we were able to do some initial
testing. We testing the vehicle four wheel
braking on asphalt as well as on dirt that we
will be required to perform to pass technical
inspection. We also tested the vehicle in a
small dirt course that included an incline and
an off camber turn where we could asses the
vehicle dynamics. From this analysis we
determined that we needed to adjust the
pressure in our front and rear shocks.
Documents: Photos
Assisted by: Ronny Gutierrez, Max Venaas

Week 9 – Baja SAE Oregon
Name: Davon Mukhar
Description: We traveled to 17 hours to
Portland to check in for the Baja SAE Oregon.
There were 100 teams from across the
country, Canada, and South America. We
were able to pass tech and compete in every
dynamic event as well as the endurance race.
Overall we achieved our goal as a team and
placed quite respectably for a first year team.
Documents: Photos

Week 10 – Year End Wrap Up
Name: Davon Mukhar
Description: Post competition for the Baja XV
team included cleaning the vehicle as well as
fixing some components that were damaged
in competition. At the end of the week there
was a track day senior commencement
ceremony where the new vehicle for the year
were displayed.
Documents: Photos
Assisted by: Entire Racecar Team

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