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1. Sub Systems Of Brakes
Brake disc
Master cylinder
Brake fluid
Brake pedal
Brake caliper
Brake fluid lines
1.Brake disc:
Material: Stainless Steel410
•Justification :Stainless steel discs offer several advantages in various applications, including motorcycle and scooter brake systems. Here are some key advantages of using
stainless steel discs.
•Corrosion Resistance: One of the primary advantages of stainless steel is its excellent corrosion resistance. Stainless steel discs are less prone to rust and corrosion, making
them durable in various environmental conditions.
•Aesthetic Appeal: Stainless steel has a polished and shiny appearance, contributing to the overall aesthetic appeal of the motorcycle or scooter. This can be especially
relevant for riders who value the visual aspects of their vehicles.
•Longevity and Durability: Stainless steel is known for its durability and resistance to wear. Stainless steel discs can have a longer lifespan compared to some other materials,
reducing the frequency of replacements.
•Reduced Maintenance: Due to their resistance to corrosion and wear, stainless steel discs often require less maintenance compared to other materials. This can result in
cost savings and increased convenience for riders.
• Heat Resistance : Stainless steel has good thermal conductivity and can handle high temperatures without deforming or losing its structural integrity. This
property is crucial in braking systems where heat is generated during braking.
• Consistent Performance : Stainless steel discs can provide consistent braking performance over a wide range of operating conditions. This consistency
contributes to the safety and reliability of the braking system.
• Ease of Cleaning : Stainless steel is relatively easy to clean, and its smooth surface makes it less prone to accumulating dirt and debris. This can be beneficial for riders
who want to keep their motorcycle or scooter in good cosmetic condition.
• Reduced Weight : While not as lightweight as some advanced composite materials, stainless steel is generally lighter than traditional cast iron. This weight reduction
can contribute to improved fuel efficiency and handling.
• Widely Available : Stainless steel is a widely available and commonly used material, making replacement discs readily accessible for riders.

2. Why we used Disc brakes instead of Drum Brakes ?
Using disc brakes instead of drum brakes in a Baja vehicle can offer several advantages, especially in off-road and high-performance applications.
1.Heat Dissipation:
Disc brakes generally dissipate heat more effectively than drum brakes. Off-road driving, especially in Baja racing conditions, can subject the brakes to intense
heat. Disc brakes are better at handling heat buildup, reducing the risk of brake fade during prolonged use.
2. Improved Cooling:
The design of disc brakes allows for better airflow and cooling, which is crucial in off-road environments where the brakes may be subjected to mud, water, and
other debris. Cooler brakes are more effective and less prone to performance degradation.
3.Reduced Fade:
Disc brakes are less prone to brake fade, a phenomenon where braking performance diminishes due to overheating. This is particularly important in off-road
racing, where consistent and reliable braking is essential.
4.Weight Considerations:
Disc brakes are often lighter than drum brakes, contributing to overall weight savings. In off-road vehicles like Baja cars, reducing weight can enhance
performance, handling, and fuel efficiency.
5.Ease of Inspection and Maintenance:
Disc brakes are easier to inspect and maintain compared to drum brakes. The components are more accessible, making it simpler to check for wear, damage, or
other issues.
6. Quick Response and Stopping Power:
Disc brakes offer quicker response times and generally provide better stopping power than drum brakes. This is crucial for off-road racing, where rapid
deceleration may be necessary.

3. 2.Master cylinder:
• Tandem Master cylinder: The reason we’re using a tandem master cylinder is because of our selection of outboard braking in our vehicle. As we’re using outboard
braking the best split system we’ll need is Diagonal Split System and a Tandem master cylinder is most suitable in diagonal split system. Using a tandem master cylinder
with an outboard braking system and a diagonal split configuration can offer several advantages in a Baja vehicle.
•Independent Diagonal Split System : Tandem master cylinders are often used in conjunction with an independent diagonal split braking system. In this configuration,
each master cylinder is responsible for braking force distribution to diagonally opposite wheels (e.g., front left and rear right, and vice versa). This design enhances
redundancy and ensures that if one part of the braking system fails, the other diagonal split remains operational, providing a degree of braking control.
•Improved Brake Balance : Tandem master cylinders allow for better tuning of brake balance between the front and rear axles. This is crucial in off-road and Baja racing
scenarios where varying terrain conditions can impact traction. Fine-tuning the brake balance helps optimize braking performance for different driving conditions.
•Enhanced Braking Control : Tandem master cylinders provide finer control over the braking system. This is beneficial in off-road situations where precise modulation of
braking force is crucial for navigating challenging terrains and maintaining vehicle stability.
•Reduced Pedal Travel:Tandem master cylinders can reduce pedal travel compared to a single master cylinder setup. This can result in a more responsive brake pedal,
providing quicker engagement of the brakes, which is essential for precise control in off-road racing.

4. • Ease of Maintenance and Adjustment : Tandem master cylinders are often easier to maintain and adjust compared to some other brake configurations. This is important
in racing scenarios where quick adjustments or repairs may be necessary between stages.
• Redundancy for Safety : The use of a tandem master cylinder with an independent diagonal split system adds a level of redundancy to the braking system. In the event of
a failure in one part of the system, the other part remains operational, improving overall safety.
• Customization for Performance : Baja vehicles often undergo extensive customization to optimize performance. Tandem master cylinders provide flexibility for
adjustments and customization to meet specific performance requirements and driver preferences.
3.Brake fluid:
• DOT4:Using DOT 4 brake fluid in a Baja vehicle offers several advantages, especially in demanding off-road conditions.
• Higher Boiling Point : DOT 4 brake fluid has a higher boiling point compared to DOT 3, making it more suitable for off-road conditions where the braking system may be
subjected to elevated temperatures. This higher boiling point helps prevent brake fluid from boiling, which can lead to brake fade.
• Improved Wet Boiling Point : The wet boiling point of DOT 4 brake fluid is higher than that of DOT 3. This is important in off-road environments where water and moisture
can enter the braking system. A higher wet boiling point ensures better performance in humid conditions, reducing the risk of brake fluid degradation
• Enhanced Heat Resistance : Off-road driving in Baja can result in extended periods of heavy braking, generating significant heat. DOT 4 brake fluid's higher heat
resistance makes it better suited to withstand the demanding conditions of off-road racing.
• Reduced Vapor Lock Risk : The higher boiling point of DOT 4 brake fluid reduces the risk of vapor lock, a condition where the brake fluid turns into vapor due to
excessive heat. Vapor lock can lead to a loss of brake pressure and diminished braking performance.
• Longer Service Life : DOT 4 brake fluid typically has a longer service life compared to DOT 3. This can be advantageous in off-road applications where maintenance
intervals may be less frequent or more challenging to perform.
• Availability and Compatibility : DOT 4 brake fluid is widely available and compatible with a variety of braking systems. This makes it convenient for Baja vehicle
owners to find suitable brake fluid and ensures compatibility with the braking components used in their vehicles.

5. DESIGN COMPARISON
 Disc Brakes:
Design: Disc brakes consist of a rotor (disc) and caliper. The rotor is connected to the wheel, and the caliper contains brake pads that squeeze against the rotor to create friction and
slow down the vehicle.
Advantages:
• Better heat dissipation, reducing brake fade.
• More effective in wet conditions.
• Easier to cool, which is essential for high-performance applications.
 Drum Brakes:
Design: Drum brakes have brake shoes that press against the inner surface of a drum attached to the wheel. The drum encases the entire braking assembly.
Advantages:
• Simple design and less expensive to manufacture.
• Self-adjusting mechanisms can compensate for brake wear.
 DESIGN VALIDATION
The need for the braking system is to increase the safety and manoeuvrability of the vehicle by statically and dynamically locking all four tires on both paved and unpaved surfaces.
Tandem Master Cylinder mounted on the front of brake pedal providing the driver with enough space. The master cylinder bore, size, calliper piston radius, and pedal ratio are
determined by doing the brake calculations.
Rotors and Callipers: The energy of vehicle motion is converted into heat; the rotors are required to dissipate a honcho amount of heat quickly and efficiently. This heat transfer is
achieved through a 4 mm thick disc with a diameter of 165.1 mm. The disc is resistant to warping and provides adequate heat transfer properties. The rotors provide better pad bite
and conditioning as well as reduce weight as much as possible. The callipers used are dual pistons with a diameter of 30mm each. It consists of a 3/4 inch bore OEM manufactured
tandem master cylinder. The pedal used has a pedal ratio of 6:1 and adequate brake line pressure is developed to bring the vehicle to stop early. Steel braided brake lines run
through the length of the car and flexible rubber lines at the A-arms. They chose due to their flexibility, strength, and ability to maintain high-line pressure values. The reliability of
our braking system improved by using the diagonal split system to ensure the safety of the driver.

6. HOW TO LOWER THE LABOUR COST
Lowering the labor cost of building a Baja buggy involves optimizing the manufacturing and assembly processes, streamlining workflows, and potentially outsourcing
certain tasks. Here are some suggestions:
•Standardize and Simplify Design : Standardize components where possible to reduce the complexity of manufacturing. Simplify the design to minimize the number of
parts and assembly steps.
•Efficient Assembly Line : Implement efficient assembly line processes to reduce the time required for assembly. Train workers to specialize in specific tasks to increase
efficiency.
•Outsource Non-Critical Tasks : Consider outsourcing tasks that don't require specialized knowledge or skills, such as simple welding or painting. Outsourcing can be cost-
effective, especially for labor-intensive processes.
•Supplier Negotiations : Negotiate with suppliers to obtain better prices for raw materials and components. Building strong relationships with suppliers can lead to cost
reductions.
•Time Management Systems : Implement time management systems to monitor and optimize the time spent on each task. This can help identify bottlenecks and areas
for improvement.
•Employee Incentives : Implement incentive programs to motivate employees to meet production targets and increase overall productivity. This can be tied to both
individual and team performance.
•Quality Control Measures : Implement effective quality control measures to minimize rework and defects. Ensuring high-quality products from the start reduces the
need for additional labor to fix issues.
•Training Programs : Invest in training programs to enhance the skills of the workforce. Well-trained employees are likely to be more efficient and produce higher quality
work.

7. DECISION AND SUPPLY SELECTION CRITERIA:
Decision Criteria:
•Cost:
1.Make: In-house manufacturing costs, including labor, materials, and overhead.
2.Buy: Supplier costs, including unit price, shipping, and potential additional fees.
3.Expertise and Capability:
4.Make: Assessing your team's skills and equipment for in-house manufacturing.
5.Buy: Evaluating the supplier's expertise, experience, and production capabilities.
•Quality Control:
1.Make: Establishing in-house quality control processes.
2.Buy: Ensuring the supplier's commitment to quality standards and inspections.
3.Flexibility and Customization:
4.Make: Ability to customize components as needed.
5.Buy: Supplier's flexibility in accommodating customization requirements.
6.Production Schedule:
7.Make: In-house production timeline and scheduling.
8.Buy: Supplier's production lead times and delivery schedules.
9.Risk Management:
10.Make: Identifying and managing risks associated with in-house manufacturing.
11.Buy: Assessing supplier risk mitigation strategies.
12.Regulatory Compliance:
13.Make: Ensuring compliance with relevant regulations for in-house processes.
14.Buy: Verifying that the supplier adheres to industry standards and regulations.

8. • Supply Selection Criteria:
1. Reputation and Reliability: Assessing the reputation and reliability of potential suppliers based on past performance.
2. Quality Assurance: Verifying the supplier's commitment to quality assurance processes and certifications.
3. Capacity and Scalability: Evaluating the supplier's production capacity and scalability to meet varying demands.
4. Financial Stability : Ensuring the financial stability of the supplier to avoid disruptions in the supply chain.
5. Geographical Location : Considering the proximity of the supplier to reduce shipping costs and delivery times.
6. Communication and Collaboration : Assessing the supplier's communication practices and willingness to collaborate.
7. Technology and Innovation : Evaluating the supplier's use of technology and innovation in manufacturing processes.
8. Environmental Sustainability : Considering the supplier's commitment to environmental sustainability and responsible practices.
9. Conflict Minerals and Ethical Practices : Ensuring that the supplier adheres to ethical business practices and avoids conflict minerals.
10. Cost and Payment Terms : Analyzing the overall cost structure and negotiating favorable payment terms.
11. Insurance and Liability : Clarifying insurance and liability terms to mitigate potential legal and financial risks.
12. Supply Chain Visibility : Ensuring transparency in the supplier's supply chain to avoid potential disruptions.
13. Contractual Agreements : Establishing clear and comprehensive contractual agreements that outline terms and conditions.

9. Make (In-House Manufacturing):
•Assess In-House Capabilities:
•Evaluate the existing manufacturing capabilities of your team or facility. Determine whether you
have the necessary expertise, equipment, and resources to manufacture the required components
in-house.
•Cost Analysis:
•Conduct a detailed cost analysis of in-house production. Consider not only direct manufacturing
costs but also factors like labor, equipment maintenance, and facility overhead.
•Quality Control:
•Implement robust quality control processes to ensure that the manufactured components meet the
required standards. Quality control is crucial for the reliability and safety of the Baja buggy.
•Prototyping and Testing:
•Invest in prototyping and testing processes to validate the design and functionality of the
components. This helps identify any issues early in the manufacturing process.
•Customization and Innovation:
•In-house manufacturing allows for greater customization and innovation. You have more control
over the design and can quickly implement changes or improvements based on testing and feedback.
•Flexibility in Production Schedule:
•With in-house manufacturing, you have more control over the production schedule. This flexibility
can be advantageous for meeting specific deadlines or adjusting to changes in demand.

10. Buy(Outsourcing):
•Supplier Selection:
•Thoroughly research and select reputable suppliers for the components you plan to buy. Consider factors such as quality, reliability, lead times, and cost-
effectiveness.
•Cost Comparison:
•Compare the cost of purchasing components from suppliers with the cost of in-house manufacturing. Include all relevant costs, such as transportation, storage,
and potential import/export fees.
•Focus on Core Competencies:
•Outsourcing allows your team to focus on core competencies, such as vehicle assembly, testing, and overall design. This can lead to increased efficiency and
expertise in your specific domain.
•Risk Mitigation:
•Outsourcing can mitigate certain risks associated with in-house manufacturing, such as equipment failures, expertise limitations, and production delays. Suppliers
may be better equipped to handle these challenges.
•Global Sourcing:
•Explore global sourcing options to find suppliers that offer competitive pricing without compromising quality. This can be particularly advantageous for obtaining
specialized components.
•Scalability:
•Outsourcing provides scalability. If demand for your Baja buggies increases, suppliers can often scale production more easily than in-house manufacturing facilities.
•Just-In-Time Inventory:
•Take advantage of just-in-time inventory practices when outsourcing. This minimizes the need for large storage spaces and reduces the risk of overstocking or
understocking.
•Contractual Agreements:
•Clearly define contractual agreements with suppliers, specifying quality standards, delivery schedules, and other critical terms. This ensures a transparent and
reliable partnership.