Design Project A

The Mg Midget came with disc brakes capable of stopping a vehicle with a curb weight of
1620lbs with its 54hp engine accounting for 320lbs. The drive train was swapped for Mazda 12a
Rx7 engine, transmission, and rear end. While the Rx7 rear end accounts for 30 lb. weight gain, the
engine came out 20lbs lighter, leaving an actual net loss of 10lbs The current hp of the 12a engine
is just shy of 118hp, requiring significant changes to the stopping ability of this vehicle.
One industry standard for evaluating a vehicles performance is its power to weight ratio. By
comparing the inverse, weight to power, of different vehicles I hope to determine a baseline for the
Mg’s new braking system. By doing so, I am relating the performance of a vehicles braking system
to it’s weight to power ratio, and thereby determining the capability of components I might use.

Design Intent: A braking system capable of handling the increased horsepower of the
Mazda Rx7 12a engine, while maintaining affordability and availability of parts. This system
must also upgrade the stock roller bearings to modern tapered bearings capable of handling
the added stresses of a larger tire used to conserve gearing ratios of the now installed Rx7
rear end. The wheel bolt pattern must be maintained, and proper offset observed to avoid
straining wheel bearings.
 Design Project A

Diagram
(Braking
Requirements)
Hp

Weight

Assumptions 1. The braking requirements may be obtained by the weight to horsepower ratio of a similar
vehicles from the era.
2. Braking style will be moderate; primary use in street application, with some track time.

3. Stock Mg Midget spindles will be used.

Governing 1. W = weight of vehicle

Equations
2. Hp= horsepower of engine
(Weight/Hp)
3. W/Hp= braking requirement

Calculations 1. Stock Mg Midget: 30 lb./hp

2. Stock Mazda Rx7: 21.2 lb./hp

3. Stock Chevrolet Camaro (same era) 20.6 lb./hp
Current
Vehicle State: W= 1620lb Hp= 118hp

1620/118 = 13.72

Solution
Check (No Errors Found)

Discussion Use w/hp calculations to determine if donor brake system is meets requirements within
reasonable safety factors. Because of assumption 2, we may conclude that braking
requirement may not exceed 20.5.
 Review: Design Project A
Design Intent: A braking system capable of handling the increased horsepower of the
Mazda Rx7 12a engine, while maintaining affordability and availability of parts. This system
must also upgrade the stock roller bearings to modern tapered bearings capable of handling
the added stresses of a larger tire used to conserve gearing ratios of the now installed Rx7
rear end. The wheel bolt pattern must be maintained, and proper offset observed to avoid
straining wheel bearings.

Was the The Design portion of this project was completed within the allotted time. The front brackets
Project were sent out to a water-jet facility, and then powder-coated. The front calipers were installed
Completed? and clearances, checked; all proved to fit as designed. Due to availability of calipers, the rear
brackets have not yet been fabricated.

Did the project The braking system used was from the same donor vehicle that the 12a rotary engine came
meet the from. This seemed most fitting due to qualifications of braking performance, and the use of
Design Intent? the Rx7 Rear axle. The rear was updated with special option rear discs, and brackets
designed to mount the calipers. The front discs were modified for a closer bearing face, and
installed onto the Mg Midget spindles. A stainless steel shim was pressed onto the spindle to
allow for proper fit of inner bearing.

What changes After fitting rear calipers, it be may determined that clearance is an issue with the smaller Mg
might you body. This may necessitate rotating the angle at which the calipers are mounted in order to
make to your maintain proper clearances.
design?

What
SolidWorks
tools were This project strongly emphasized the use of 2d sketch tools, proper geometrical constraints,
most and dimensional tolerances. Reference geometry was also helpful in creating the two piece
beneficial in rear caliper bracket.
designing this
project?

Did you meet

Because the majority of this projects design was developed on a single plane, this was an
the objectives
ideal problem to begin with. Use of the extrude and revolve feature tools were used, as
outline in the
expected, and multiple parts gave opportunity to become familiar with SolidWorks drawing
Project
environment.
Proposal?