•SAE Baja is an Inter-colligate off road racing competition where the top engineering colleges in India successfully fabricate and race there all-terrain vehicles. •The competition has various automotive giants like Mahindra, General motors etc. powering the event. •The contest challenges each team to function as a firm whose objective is to design, fabricate, market and race off their vehicles that would be evaluated on a variety of manufacturing angles by various professionals from the sponsoring automotive companies.

1. DAYANANDA SAGAR COLLEGE OF ENGINEERING
BANGALORE

2. TECHNICAL
FEATURES

3. VIEWS
ISO SIDE
TOP
FRONT

4. ROLL CAGE DESIGN
MATERIAL
TUBINGS
SAE 1018
MILD
STEEL
WALL THICKNESS 3mm
COCKPIT
DIMENTIONS
1000*700m
m2
LENGTH 84.52 in
HEIGHT 31.49 in
WIDTH 61 in
No. OF WELDS 44
WELD LENGTH 46.2 in
TUBE Od 27mm
TOTAL WEIGHT 70 kg

5. FRONT ANALYSIS
Material AISI 1018 Steel
Density 7.7 Kg/m^3
Yield Strength 386 MPa
Tensile Strength 634 MPa
Poisson's Ratio 0.27-0.3
Material Specification
Analysis Results
Maximum
Stress
124.88 MPa
Maximum
Displacement
1.4411 mm
Acceleration 3g

6. REAR
ANALYSIS
Material AISI 1018 Steel
Density 7.7 Kg/m^3
Yield Strength 386 MPa
Tensile Strength 634 MPa
Poisson's Ratio 0.27-0.3
Material Specification
Analysis Results
Maximum
Stress
269.557 MPa
Maximum
Displacement
4.4239 mm
Acceleration 3g

7. SEAT AND ENGINE
ANALYSIS
Material AISI 1018 Steel
Density 7.7 Kg/m^3
Yield Strength 386 MPa
Tensile
Strength
634 MPa
Poisson's Ratio 0.27-0.3
Material Specification
Analysis Results
Maximum
Stress
19.4926 MPa
Maximum
Displacement
0.3291 mm
Load 146 kgf

8. SIDE ANALYSIS 1 SIDE ANALYSIS 2
ROLL OVER ANALYSIS ROLL OVER
ANALYSIS

9. POWER TRAINENGINE SPECS
• Briggs and Stratton
• Model 205432/205332
• Power = 10HP
• Compression Ratio= 8:1
• Torque = 18.6Nm at
2600rpm
• 305 CC
• Four Stroke
Gear R Overall ratio Max speed kmph Tractive force (N) Acceleration(m/s*s ) Gradeability%
1st 31.48:1 12.42 1798.66 5.45 45.56
2nd 18.7:1 20.91 1068.46 3.237 23
3rd 11.4:1 34.3 651.358 1.97 10.12
4th 7.35:1 53.2 419.95 1.27 2.97
rev 55.08:1 7.1 3147.09 9.5366 87.2134
For TIRE DIAMETER 22 inch, max speed at red line rpm is 48.77kmph
For TIRE DIAMETER 24 inch, max speed at red line rpm is 53.2kmph
Therefore selecting 24 inch diameter for the rear tire :
Taking,
N = Transmission Efficiency = 0.8
Mo =Gross mass of the vehicle = 330 kg
Fr=Coefficient of rolling friction for vehicle on dirt track = 0.1
TRANSMISSION:MAHINDRA CHAMPION ALFA

10. CHAIN COUPLING
MATERIAL MS1024
PITCH 12.7mm
NO OF TEETH 15
PITCH DIA 62mm
VELOCITY 8m/s
REQUIRED
PULL
2138N
ALLOWABLE
PULL
1137.5
NO OF
STRANDS OF
THE CHAIN
2
LENGTH OF
CHAIN
1194mm
MAX
DIFFERENCE
BETWEEN 2
CENTERS
550mm
DIAMETER
REAR AXLE
CALCULATIO
NS
MATERIAL SOLID STEEL
8620
TORQUE=F
OS x GERA
RATIO x
MAX
ENGINE
TORQUE
T= 2x 55.08x
19
= 2093.04 N-
m9
T=(p/16) x t
xdo
3
MAXIMUM
PERMISSAB
LE SHEAR
STESS
“T”
T=897x 10^6
N/m2
T=2093.04
Nm
2093.04=(3.14
/16)x 897x
10^6 Xdo
3
Do
3=1.19x 10-5
Do=0.0228
Do= 22.8mm
MAX SHEAR
STRESS
DUE TO
ENGINE
TORQUE
897/2= 448.5
N/mm2
TRANSMISSION Rpm vs Speed
Rpm vs
Tractive
effort

11. TYPE : OUTBOARD
UNEQUAL(FRONT) DOUBLE
A ARMS WITH ADJUSTABLE
CAMBER USING BALL
JOINTS
SHOCK ABSORBERS: COIL
OVER DAMPER
ROLL CENTRE HEIGHT : 4”
CAMBER ANGLE : 0
DEGREES
CASTOR ANGLE : +5
DEGREES
CASTOR TRAIL : 2.43
cm
TOE : 0
DEGREES
SPRING MATERIAL : CHROME VANADIUM STEEL
FRONT REAR
SPRING
STIFFNESS
7.8956 N/mm 11.8435
N/mm
DAMPING
FACTOR
0.3 0.3
DAMPING CO
EFFICIENT
0.377NS/mm 0.565NS/mm
DAMPED
NATURAL
FREQUENCY
1.9078 Hz 1.9078 Hz
DESIGN
WIRE DAIMETER 10 mm 12
MEAN COIL
DIAMETER
80 mm 96
NO OF TURNS 25 20
FREE LENGTH 460.5 mm 454.5
PITCH 17.62mm 21.525mm
SUSPENSIONS

12. SUSPENSION ANALYSER
FRONT TOP A-ARM
ANALYSIS
DIVE CASTE
R Lt.
CASTE
R Rt.
CAMBE
R Lt.
CAMBE
R
Rt.
RC Lt/
RT,in
LT
RC Lt/
RT,in
RT
RC
Ht,
In LT
RC Ht,
In RT
SCRU
B
In LT
SCRU
B
In RT
.000 3.951 3.951 .000 .000 .000 .000 3.997 3.997 .000 .000
-.500 3.955 3.955 .668 .668 .000 .000 4.860 4.860 .127 .127
-1.00 3.960 3.960 -1.098 -1.098 .000 .000 5.704 5.704 .361 .361
-1.50 3.966 3.966 -1.436 -1.436 .000 .000 6.504 6.504 .659 .659
-2.00 3.975 3.975 -1.737 -1.737 .000 .000 7.367 7.367 1.010 1.010

13. STEERING > MODIFIED MARUTI 800 RACK
AND PINION
WHEEL TRACK 67in
WHEEL BASE 58in
STEERING AXIS
INCLINATION (SAI)
12°
SCRUB RADIUS 7.8mm
ACKERMANN ANGLE 17 °
TIE ROD LENGTH 38.29 in
INNER STEERING ANGLE 44°
OUTER STEERING ANGLE 31.5°
TURNING RADIUS 3.38m
STEERING RATIO 9.7:1
STEERING WHEEL
LOCK TO LOCK
610°
STEERING

14. Brake Components & Remarks
Components
• All 4 Disc combination used to
achieve 4 Wheel Lock .
• Disc Used – Apache RTR 180
(Rear)
• Caliper Used – 3Apache RTR
180 (Front) and 1 Honda
Aviator
• Master Cylinder Used – Maruti
800 Bosch Tandem Master
Cylinder (OEM)
• Aluminum Brake Lines,
Hydraulic Brake hoses, Banjo
bolts etc.
Remarks
• The Disc and Calipers being
used are the same as previous
year. The reason being its
Reliability and to ease up the
Budget. (Spares will be bought
in case any malfunctions.)
• This particular combination of
Calipers is chosen due to its
Ease of Mounting Bleeding
points on top.
• Bosch Tandem Master cylinder
is used because of its
Compatibility with the Calipers
and BAJA recommends use of
OEM.
• Diagonal Braking Circuit Split
used so that braking power is
available on both Axles in case

15. BRAKING SYSTEM & CIRCUIT
SPECIFICATION
S
VALUE
DISC DIAMETER
Outerinner
200mm/170mm
CAPILER
PISTON/MASTER
CYLINDER
DIAMETER
20mm/20mm
BRAKE FORCE (N) 2750.55 N
STOPPING
DISTANCE
13.516 meter
(54.0 Km/hr)
STOPPING TIME 1.8 +0.3+0.75 sec
(54.0 Km/hr)
DECELERATION 8.3235m/s^2
DECELERATION avg. 5.26m/s^2
PEDAL FORCE 40 kg
SPECIFICATIONS VALUE
PEDAL RATIO 7:1
STATIC AXLE LOAD
(FRONTREAR)
582.714N/
2654.6N
DYNAMIC AXLE LOAD
(front/rear)
896N/
2341N
WEIGHT TRANSFER 808.48N
BREAKING TORQUE 582.38N-m
TRACTION FORCE ON
SLOPE
2289.117N
CYLINDER PRESSURE 7.876MPa
MASTER CYLINDER
LOSSES
0.125cc

16. ELECTRICALS
BATTERY
12 V
HEAD LAMP
15W
HORN
10W
REVERSE
LIGHT
3W LED
REVERSE
ALARM
10W
BRAKE
LIGHT
5W

17. SAFETY & ERGONOMICS
• 2 Kill switches (ski do type) are fitted at the dashboard and
the top right corner of the vehicle.
• SFI & FIA Certified Race Suit, 5 Point Seat belt. Certified
Motocross Helmet, Gloves, Neck Brace, British standard
Goggles & Arm Restrainers.
• The figure below suggests that the driver can exit & enter
from the vehicle conveniently within 5 seconds as
suggested in the rule book.
BINOCULAR VIEW

18. DESIGN FAILURE MODE EFFECTS ANALYSIS
PART FUNCTION FALIURE MODELS PRECAUTIONS
ROLL CAGE TO PROTECT THE DRIVER WHEN MATERIAL
REACHES THE ULTIMATE
STRESS VALUE
USE OF AISI 1018 STEEL
HAVING YEILD STRESS
VALUE OF 386 MPa
ENGINE TO GENERATE POWER • SPARK PLUG FAILURE/
IMPROPER FUNCTIONING
• OLD FILTER
• REGULAR CHECK OF
SPARK PLUG
• FILTER CHANGE
TRANSMISSION TO TRANSMIT POWER
FROM ENGINE TO WHEELS
IMPROPER LUBRICATION/
UNEXPECTED LOAD
USE OF ISO GRADE OILS.
SUSPENSION TO ABSORB SHOCKS WHEN COIL REACHES TO
SOLID LENGTH
PROPER ASSUMPTIONS IN
DESIGNING.
STEERING TO STEER THE VEHICLE BREAKING OF TIE ROD TIE ROD PLACED BEHIND
THE FRONT A-ARMS
BRAKES TO REDUCE THE SPEED
WHEN REQUIRED AND TO
PANIC STOP
• CIRCUIT FALIURE DUE
TO LEAKAGE
• WORNOUT BRAKE
PADS
• BLEEDING THE
BRAKES BEFORE
EVERY RUN
• REGULAR CHECK AND
REPLACEMENT
WHEELS TO PROVIDE GOOD
TRACTION
• INAPPROPRIATE AIR
PRESSURE
• PUNCTURE/TEAR
• CHECK THE AIR
PRESSURE AT EACH
REFUEL
• SPARE TIRES

19. Vehicle Statistics
Number of wheels 4(not in a straight line)
Width 64”
Length 108”
Driver’s weight & height 113.4kg & 6’3”
Top speed 60km/hr
Engine Statistics
Required engine B&S
Displacement 338 cc
Power 11hp/8 kW
Spark plug RC12YC
Idle speed 1300+/-100
Air filter inlet diameter 22mm
Governor setting 3600 r.p.m(max)
Fuel tank capacity 6 litre
Exhaust System
Muffler’s Back pressure 450mm of water column
Exhaust pipe Any length
Exhaust pipe clearance
dimension
100mm(min.)
Battery Requirements
Battery 12V, 44Ah
Transponders
Orientation Vertical to frame
Location 24” above the track(max.)
Roll cage material specifications
Outer diameter 1”(min.)
Wall thickness .12”
Carbon content .18%
Miscellaneous
Driver’s exit time 5 seconds
Firewall thickness .020”
Fire extinguishers 1 litre(min.)
Shoulder harness mounting 7” to 9”
Drip pan diameter 8”
Head restraints
Minimum area 36sq inches
Density of padding 50-100kg/m^3
Minimum thickness 1.5”
Head clearance from seat 41”
Head clearance from helmet 6”
Rule Book Compliance

20. 2012 2013
Anti Ackerman steering Ackerman steering geometry
Engine Mounting: Direct Coupling Chain Sprocket is used
A Bumper was provided No bumper is provided
Bolt and nut pivot was used Ball Joint pivot is used
Equal and Parallel A-Arms Unequal and parallel A-Arms
Tie-rod was in front of the A-Arms Tie-rod is behind the A-Arms
Tyre size: Front 21in, Rear 22in Tyre size: front 22in, Rear 24in
VARIATIONS IN DESIGN

21. VARIABLE CHAMBER MECHANISM - The variable camber mechanism is a
modification in the front suspension design which will allow us to vary the
camber angle at will. This is done through using adjustment bolts which will
help vary the distance between the upper knuckle joint and the chassis.
Camber can be varied in test runs and the optimum camber can be decided for
the particular condition.
INDEPENDENT FENDERS-The fender is a removable
attachment to the A-arms of the suspension which help
to block dirt & sludge away from the driver. It is
mounted on the A-arms using pipe brackets hence
avoiding drilling of any holes. The assembly is spring
loaded allowing it to undergo slight deflections and not
making it rigid and prone to failure.
INNOVATIONS

22. MARKETING
&
SPONSORSHIP

23. SOCIETY OF AUTOMOTIVE ENGINEERS
(SAE)
• A non-profit organization based at Detroit, USA
• Working with a mission to enhance human capability of Mobility Engineering
professionals – air, land and sea.
• It strives to achieve it through
• Establishing engineering standards
• Professional Development Programmes
• Capturing the latest technology and trends
• Research publications
• Seminars & Conferences – APAC, SIMC, etc.
• Student Development Programmes
• Student Convention
• BAJA SAE
• Formula SAE
• AeroDesign
• The society has over 100,000 registered members across the globe. It operates globally
through its national chapters and affiliations with other bodies such as FISITA, etc.
• The Indian chapter contributes maximum number of members – 25000 registered
members

24. INDUSTRIAL AFFILIATION OF BAJA
SAEINDIA
Dassault Systemes
Delphi
Mahindra & Mahindra
Mahindra Navistar
Maruti Suzuki
NATRIP
EASI
Eaton
EMITEC
ETAS
Precimaxtech
PTC
Sundaram Clayton
Toyota Kirloskar Motors
FIAT
Fleetguard
Force Motors
FORD
TVS Motors
UCAL Fuel
Varroc
Volvo India
ZF Steering
Ever since its inception, the event has been
well received by the industry. Some of the
associates of BAJA SAEINDIA include:
Anand Automotive Systems
Gabriel
GM India
HCL
Ansys
ARAI
Ashok Leyland
AVTEC
ICAT
ITW Chemin
JK Tyres
John Deere
Boeing
Bosch
Bharat Petroleum
Brakes India
Johnson Matthey
Liugong
Lombardini
Cumminsa

25. SAE INDIA BAJA
 Baja is an inter-collegiate design
competition organized by the Society of
Automotive Engineering (SAE)
Provide Indian students with a
standard platform to showcase their
talent and potential not only in terms of
design and engineering, but also their
capability for team-work, entrepreneurial
skills and management.
The contest challenges each team to
function as a firm, whose task is to
design, fabricate, market and race-off an
off-road vehicle that will be evaluated on
a variety of manufacturing angles.
The vehicles are judged based on their
ability to maneuver and transverse harsh
off-road racing course while not
succumbing to the rigors of it.

26. TEAM KASHPIERS @ DSCE
» Started in May, 2010.
» With a mission of meeting the necessities and requirements of the
industry by gaining practical knowledge and hands-on-experience.
» Amongst the Top-3 Collegiate Clubs in the Nation in terms of
Members Strength, with 800+ members as of today.
» One of the most active Collegiate Clubs in the Country with atleast
one event in a fortnight!
» Hosted a NATIONAL EVENT in just 14 months since formation.
» XXX, Princeton Review , Global Solution , Briggs and Stratton are
few of our previous years’ sponsors.

27. STATUS UPDATE
10
59
68
84
39
ZONE WISE DISTRIBUTION
EAST
WEST
NORTH
SOUTH
CENTRAL

28. THE BAJA STORY
2009 2010 2011 2012 2013
54
75 80
100
130106
146
198
250
300
BAJA MAIN EVENT
VIRTUAL BAJA

29. MEDIA PRESENCE

30. SPONSORSHIP BENIFITS
• The Company will gain ETHICAL value and provide moral support for the budding
engineers of the future.
• Company name will be placed with Team name in all BROCHURE, college
NEWSLETTER(Teckriti) , ANNUAL COLLEGE FESTS & AUTO EXPOS (Bangalore).
• BANNERS, PORSTERS, FLYERS of specific sizes will be displayed on campus
• The event is sponsored by various industrial giants like MAHINDRA , JK TYRE, ANSYS
• Print, Television, Radio media like DNA, DECCAN HERALD, TV 9 supporting the Team
• The company name will be published in the team WEBSITE.
• The company name will be displayed on the car at all times, bring it into the limelight.
• The competition will be witnessed over 5000’s of graduating engineers attracting them
to the company
• The company will be displayed on the PARKING SLIP which will have a distribution rate of
600 per day.
The event will be witnessed by various GM, CEO & MD’s of the public and private
sector companies.

31. FRONT VIEW SIDE VIEW
• The company will also feature on the helmets, Team T-shirts, Driver uniform,
Pit area, Bags, Business Cards & College Magazines
• The sponsoring company can use the college premises for advertisement and
publicity
SPONSORS’ SPACE

32. COST REPORT
PARTICULAR Bill Amt in Rs Currently
1. VIRTUAL REGISTRATION 15,000/- Sponsored by college
2. BAJA REGISTRATION 35,000/- Sponsored by college
3. MATERIAL (CHROMOLY OR MILD STEEL 1024) 35,000/-
4. FORGING 3,000/-
5. TOOLS 25,000/-
6. FABRICATION 25,000/-
7. STEERING 5,500/-
8. SUSPENSION & ASSEMBLY 30,000/-
9. BRAKES 16,330/- Sponsored by TVS
10. TYRES 60,000/- Sponsored by CEAT
11. NUTS&BOLTS 3,000/-
12. FIBERGLASS 5,000/-
13. ELECTRICALS 4,000/- Sponsored by Minda
14. PAINT 5,000/-
15. TRANSMISSION
16. ENGINE (SERVICE)
17.TRANSPORT TO VENUE ( WITH INSURANCE)
18. TEAM TRAVEL AND ACCOMODATION
25,000/-
6000/-
25000/-
60000/-
TOTAL 3,82,300
Sponsored by B&S

33. ENGINE & DRIVE
35%
TRANSMISSION
11%
STEERING
2%
SUSPENSION
8%
FRAME & BODY
7%
BRAKES
6%
ELECTRICAL
2%
SAFETY
13%
MISCELLANEOUS
16%
MAJOR COST BREAKUP
GRAND TOTAL OF THE PROJECT : 3,82,300
…….

34. Monetary Assistance – Fund our project where we both benefit on the long run. Your company logo
will be placed on various parts of the vehicle as well as on the driver’s apparel and helmet . PUBLICITY.
Parts & accessories - Numerous parts are required in building the ATV like shockers , welding rods ,
frame /chassis metal , steering, speedometers, electrical systems, ignition systems and other
components.
Any material assistance is appreciated and the company logo will be placed on the vehicle.
Benefits depends one the cost of the part/material.
Technical Assistance – Our design team will require technical assistance frequently in order to solve
real time problems . Your help will be greatly appreciated as technical sponsor and company logo will be
advertised on the vehicle .Benefits depends on the level Assistance.
Travel sponsors- our entire team will require to travel to various destinations across the country to
compete and exhibit our vehicle .Also the cost of 20 people traveling for the competition. All Benefits will
be provided to the sponsor. They will fall into the silver sponsor category.
Transport sponsor- The team will require frequent delivery of parts for various places. A major portion
of the cost will be incurred on transporting the car to the venue. This sponsor will fall into the Silver
sponsor catogery
Media Sponsors – The entire team and the vehicle will have exclusive media coverage during the
making as well as participation in the rally which will propagate your company’s presence as a sponsor
.Social, Television, Radio, Print .
NOTE- Details on the size, location, Frequency of distribution of banner, posters, flyers, brochures,
newsletters, advertisement spaces and social media publicity will be provided.
Regular updates will be provided to all sponsors.

35. TITLE PLATINUM DIAMOND GOLD SILVER BRONZE
Name to be
placed before
team name
* - - - - -
Flex Banners
8ft x 6ft 8ft x 4ft 6ft x 6ft 6ft x 4ft 4ft x 4ft 3ft x 2ft
Company Logo
in the PIT
LANE
FRONT BACK SIDE SIDE SIDE WORKSH
OP
Part of
placement &
training
program * * * - - -
Hyperlink to all
associated
sites FIRST SECON
D
THIRD FOURTH FIFTH SIXTH
Name of Co.
on the
brochure
FRONT
BACK
INSIDE
FRONT
BACK
INSIDE
FRONT
BACK
INSIDE
BACK
INSIDE INSIDE INSIDE
Logo on Team
Apparel
* * * * * *

36. DESIGN
1-Suhas VR
2-Sagar M
3-Abhishek M
DESIGN
ELECTRICALS &
BRAKES
1-Apoorv B
2-Avijit P
POWERTRAI
N
1-Hansel P
2-Vinay SN
3-Dheeraj J
4-Huzefa P
5-Divyanshu P
MARKETING
1-Mohit M
2-Anurag S
3-Gaurav A
4-Siddhart P K
SUSPENSION
1-Varun J
2-Deepak K
STEERING
1-Pavan K
2-Girish P

37. THANK YOU
TEAM KASHPIERS