Mechanical

1
Mechanical

• BY David Hardy
• And
• Matt Carter

2
Safety

• Work Safely- wear personal protective equipment
  when working on the car
• Safety goggles/facemask (including welding
  masks!)
• Protective clothing
• Gloves
• Closed-toe shoes
• Adequate Equipment- make sure your tools are in
  safe working order. Check power tools for loose
  parts, frayed wires, or anything else that just
  doesnt look right.
• Safe Design- follow or go beyond all rules and
  regulations (roll cage,etc.). Remember that you
  are irreplaceable and that your car is VERY
  expensive to repair!

3
Steering

• Keep it simple
• Make the steering system easy to operate, repair,
  and maintain.
• Rack and pinion is highly recommended
• Make sure that you meet the turning radius rules
  for scrutineering.
• A power steering apparatus may sound like great
  idea but they are heavy, difficult to operate,
  and messy.

4
Brakes

• Hydraulic disc brakes are ideal!
• Lightweight, easy maintenance, all shapes and
  sizes to suit your cars weight.
• Mechanical brakes have inherent design flaws and
  are prone to fail!
• Drum brakes are bulky and inefficient.
• Mount brakes securely to car!
• Familiarize yourself with the ins and outs of how
  your braking system(s) work.
• Test, test, TEST!
• Drivers should have full confidence in slamming
  on the brakes.

5
Wheels and Tires

• Ideally, wheels should be lightweight and durable
  enough to support the car.
• Historically, wire spoke wheels have not been a
  safe option.
• Become very familiar with how to mount and remove
  the wheels from the car, and always have a spare!
• The most popular tires in high school solar
  racing are Bridgestone Ecopia tires.
• High-pressure tires with a thin vertical profile
  are ideal.
• Become very familiar with how to change tires off
  the wheels quickly.

6
Motor

• Expect expensive, but search for all your
  options.
• Hub motors are gaining popularity, but are
  expensive.
• If not using a hub motor, decide which type of
  drive works for your car chain, belt, or direct,
  for example.
• Experiment with the gearing of your drive system.
  There is no simple, set formula to gear ratios,
  so find what works for your car.

7
Suspension

• Suspension types, designs, and cost vary greatly
  by vehicle. Find what works with your budget and
  vehicle.
• Familiarize yourself with how to make small and
  large adjustments for the varying conditions your
  car will go through.
• Learn how to keep your wheels correctly aligned.
  This will save you on tires and other wear
  and tear on your vehicle.

8
Summary

• Safety is the key element of building every
• aspect of your car. If you work with safety in
• mind, your cars structure will be both durable
• and efficient.