BAJASAEINDIAVirtualDesignChallenge2009

RulebookVersion:June2009 C/o:SAEINDIANorthernIndiaSectioninaegisSAEINDIA

BAJASAEINDIAVirtualDesignRulebook

SECTION1
GENERALINFORMATION
Page|2 TheSAEMiniBajaCompetitionoriginatedattheUniversityofSouthCarolinain1976,underthedirection ofDr.JohnF.Stevens.Sincethenthecompetitionhasgrowntosixcompetitions:threeinNorthAmerica and one each in Brazil, Korea and South Africa with over 500 entries. With the growth of the series, corporationshavecometorecognizethatstudentswithBajaSAEontheirresumesarepremiercandidates fortheirengineeringpositions. From the 2007 Collegiate Design Series, SAE announced the name of Mini Baja competitions for rugged, singleseat,offroadrecreationalvehiclesasBajaSAE.Thischangebroughtthenameoftheoffroaddesign events into consistency with that of the wellknown Formula SAE design competitions for autocross vehicles.Duringthesameyear,underthedirectionofDr.PawanK.Goenka(formerSAEINDIAPresident) and the convenership of Dr K.C Vora (Secretary, SAE India) BAJA SAEINDIA, the maiden BAJA SAE INDIA Series was conducted at the NATRAX (National Automotive Test Tracks) facility of NATRIP (National AutomotiveTestingandR&DInfrastructureProject),Pithampur,MadhyaPradesh,inDecember2007.The eventwitnesseditssecondyearinJanuary2009atNATRAX.ThenextBAJASAEINDIAEventisslatedforJan 29th31st2010witnessingparticipationfromAsianSubcontinent. TheVirtualBAJASAEINDIADesignChallenge,auniqueadditiontotheBAJASAEINDIASeriesoriginatedin the year 2008 under the Convenership of Dr N Karuppaiah, BAJA SAEINDIA, Mr N Balasubramanian and Mr S Shanmugham, CoConvener, BAJA SAEINDIA Virtual Design Challenge. The second Design Event is slatedforOct2009. 11.1BajaSAEINDIADesignChallengeObjective Baja SAE INDIA is an intercollegiate engineering design competition for undergraduate and graduate engineeringstudents.Theobjectofthecompetitionistosimulaterealworldengineeringdesignprojects and their related challenges. Each team is competing to have its design accepted for manufacture by a fictitiousfirm.Thestudentsmustfunctionasateamtodesign,build,test,promoteandcompetewitha vehiclewithinthelimitsoftherules,alsotogeneratefinancialsupportfortheirprojectandmanagetheir educationalpriorities. 11.2CompetitionGoals Eachteamsgoalistodesign,analyzeandvalidateamodelofarugged,singleseat,offroadrecreational vehicleintendedforsaletothenonprofessionalweekendoffroadenthusiast.Thedesignmustbesafe, complyingtorulesasdiscussedandfeasibleformanufacturability.Thetopthree(3)winningteamswould bemotivatedtofabricatetheirdesignsforfurtherparticipationintheBAJASAEASIA2010MainEvent. 11.3TheSAEBajaSeries TheBajaSAESeriesconsistsofsevencompetitions.ThreecompetitionsareheldinNorthAmericaunder thesponsorshipofSAE: BajaSAEAlabamaHostedbyAuburnUniversity BajaSAEOregonHostedbySAEOregonSection BajaSAEWisconsinHostedbySAEMilwaukeeSection

11.Overview

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BajaSAEcompetitionsheldinAfrica,AsiaandSouthAmericaareassociatedwithSAE,butorganizedand sponsoredbytheirlocalhosts: BajaSAEBrazilSponsoredandhostedbySAEBrazil. BajaSAEKoreaSponsoredandhostedbyYeungnamUniversity. BajaSAESouthAfricaSponsoredbySasolandhostedbytheUniversityofPretoria. BajaSAEIndiaSponsoredandHostedbySAEINDIA&conductedatNATRAX,Pithampur. Page|3 Baja SAE India Virtual Design Challenge Sponsored and Hosted by SAE INDIA & conducted by SAE NorthernIndiaSection AllBajaSAEcompetitionshaveopenregistrationpoliciesandacceptteamsofuniversitystudentsfromany country. Baja SAE India Design Challenge will accept teams only from Asia. Some sections of rules governing Baja SAE events held outside India are specific to those competitions. Such variations are publishedontheindividualwebsites. 11.4OfficialAnnouncementsandCompetitionInformation TeamsarerequiredtoreadthearticlespostedontheBajaSAEIndiahomepage(http://bajasaeindia.org) published by SAE India and the other organizing bodies. Teams must also be familiar with all official announcements concerning the competitions and rule interpretations released by the Baja SAE India TechnicalCommittee.TheofficiallanguagefortheBajaSAEIndia2010EventisHindiandEnglish.

12.BajaSAEIndiarulesandorganizingauthority
12.1RulesAuthority TheBajaSAEINDIArulesaretheresponsibilityoftheBajaSAEINDIADesignChallengetechnicalcommittee and are issued under the authority of the SAE India. Official announcements from the Baja SAE INDIA technicalcommittee,SAEIndiaortheotherBajaSAEINDIAorganizersshallbeconsideredpartofandshall havethesamevalidityastheserules.Ambiguitiesorquestionsconcerningthemeaningorintentofthese rules will be resolved by the SAE India Technical Committee, SAE India or by the individual competition organizersasappropriate. Generalqueriesmaybeaddressedtoinformation@bajasaeindia.org. 12.2RulesValidity The Baja SAE India Rules posted on the Baja SAE INDIA website and dated for the calendar year of the competitionaretherulesineffectforthecompetition.Rulesetsdatedforotheryearsareinvalid. 12.3RulesCompliance ByenteringaBajaSAEINDIAcompetition,theteam,membersoftheteamasindividuals,facultyadvisors and other associated personnel agree to comply with, and be bound by, these rules and all rule interpretationsorproceduresissuedorannouncedbySAEIndia,theBajaSAEIndiaTechnicalCommittee and the other concerned organizing bodies. All team members, faculty advisors and other associated representatives are required to cooperate with, and follow all instructions from, competition organizers, officialsandjudges. 12.4UnderstandingtheRules

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Teamsareresponsibleforreadingandunderstandingtherulesineffectforthecompetitioninwhichthey areparticipating.Thesectionandparagraphheadingsintheserulesareprovidedonlytofacilitatereading; theydonotaffecttheparagraphcontents. 12.5ParticipatingintheCompetition Page|4 Teammembersasindividuals,facultyadvisorsandotherrepresentativesofaregisteredcollegewhoare presentonsiteatacompetitionareconsideredtobeparticipatinginthecompetitionfromthetimethey arrive at the event site until they depart the site at the conclusion of the competition or earlier by withdrawing. 12.6ViolationsofIntent Theviolationoftheintentofarulewillbeconsideredaviolationoftheruleitself.Questionsaboutthe intent or meaning of a rule may be addressed to the Baja SAE India Technical Committee, Technical InspectorsorSAEIndia. 12.8GeneralAuthority SAE India and the competition organizing bodies reserve the right to revise the schedule of any competition and/or interpret or modify the competition rules at any time and in any manner that is, in theirsolejudgment,requiredfortheefficientoperationoftheevent.

13.Eligibility
13.1IndividualParticipantRequirementsEligibilityislimitedtoundergraduateandgraduatestudentsto ensure that this is an engineering competition rather than a race. Individual members of teams participatinginthiscompetitionmustsatisfythefollowingrequirements: 13.1.1StudentStatus Teammembersmustbeenrolledasadegreeseekingundergraduateorgraduatestudentinacollegeor university. Team members who have graduated during the last seven (7) month period prior to the competitionremaineligibletoparticipate. 13.1.2SocietyMembership TeammembersmustbecurrentmembersofSAEIndia.Proofofmembership,suchasmembershipcard,is requiredatthecompetition.Inaddition,theparticipatingteamsmusthaveanactiveSAECollegiateClubat theirschool. Note: More information regarding SAE membership and Collegiate clubs can be found at: www.saeindia.orgorwww.bajasaeindia.org.

14.Registration
TeamsarerequiredtoregisterattheBAJASAEINDIAWebsite.Alltheupdateswouldbeputuponlineand itisthesoleresponsibilityoftheteamtocheckforupdates. 14.1MaximumEntriesperCollege

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Acollegecanhaveanynumberofteams,subjecttoapprovalforfinalparticipationfromtheBajaSAEIndia Secretariat. 14.2RegistrationDeadlinesandfees Registration fee would be collected in different stages as per the Flow Chart attached. Virtual BAJA Page|5 participantswouldberequiredtopayRs.25,000/altogether.Theprocessisevidentfromthefollowing FlowChart,whichalsoincludesthetentativedeadlines.RegistrationfeesareNOTrefundable.

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Section2VehicleRequirementsandRestrictions
20.GeneralDesignRequirements
Acollegecanhaveanynumberofteams,subjecttoapprovalforfinalparticipationfromtheBajaSAEIndia Page|6 Secretariat. 20.1VehicleDesignObjective The vehicle design should be attractive to consumers because of its visual appearance, performance, reliabilityandeaseofoperationandmaintenance.Itshouldalsobemanufacturableusingpredominantly semiskilledlaborandstandardmachinetools.Safeoperationmustbeanessentialconsiderationinyour design. 20.2VehicleConfiguration The vehicle must have four (4) or more wheels not in a straight line. Three (3) wheeled vehicles are prohibitedfromthecompetition.Thevehiclemustbecapableofcarryingone(1)person190.3cm(63) tallweighing113.4kg(250lb). 20.2.1MaximumVehicleDimensions Width:162.56cm(64in)atitswidestpoint(thewidestpointofthevehicleandnotnecessarilythewheel trackwidth)withthewheelspointingforwardatstaticrideheight.Vehiclesexceedingthisdimensionwill notbeallowedtoruninanydynamicevent.Agonogodevicetocheckthisdimensionmaybemade availablebytheorganizers. Length:Unrestricted,butseenotebelow. NOTE: Teams should keep in mind that Baja SAE India course at Pithampur is designed for vehicles with maximumdimensionsof64inwidthby108inlength. 20.3AllTerrainCapability Thevehiclemustbecapableofsafeoperationoverroughlandterrainincludingobstructionssuchasrocks, sand, jumps, logs, steep inclines, mud and shallow water in any or all combinations and in any type of weatherincludingrain,snowandice.Thevehiclemusthaveadequategroundclearanceandtraction.

21.RequiredEngine
LombardiniLGA34011hpengine Thedrawingsoftheengineasrequiredfordesigningtheprototypeareasattachedintheannexure. 21.1AirCleaner The air intake system should be designed by the participating teams, complying with the engine specificationsandusingsoundengineeringpractices. 21.2ExhaustSystem

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(a)MufflerAnymufflerwhosebackpressuredoesnotexceed450mmofWaterColumnmaybeused. Other exhaust systems are prohibited. All exhaust gas must pass through a single muffler. Multiple mufflersarenotallowed. (b) Muffler Relocation If the car design requires an exhaust system reconfiguration to keep it from Page|7 impingingonpartofthecar,thereroutingmustbedoneusingtubinghavinganIDof32mm&ODof35 mm.Anyremotemountedexhaustsystemmustbesecurelymountedsothatitdoesnotvibrateloose duringthecompetition. (c)MufflerSupportSupportoftheexhaustpipeandmufflerarestronglyrecommended. (d)ExhaustPipeExhaustpipemaynotprotrudeinsideofexhaustportsoastoalterportconfiguration. (e) Exhaust Pipe Length Any exhaust pipe length is allowed, however pipe length cannot be adjustable. (f)ExhaustPipeHoles&TubesNoextraholesortubesareallowedintheexhaustpipe. (g) Exhaust Pipe Durability Required The exhaust pipe and muffler must be completely intact and operationalthroughouttheevent,andshallbegroundsforpenaltyordisqualificationifnotintactatthe endofanyevent,includingenduranceevent. 21.3FuelSystem Afueltankcapacitymaynotexceed6litres.Onlyonefueltankisallowedtobemountedinthevehicle. 21.4OnboardInstrumentation/DataAcquisition Onboard instrumentation/data acquisition is allowed; the power for this instrumentation must be from approvedbatteriesasper21.4.15.Ensurethattheaboveitems/systems,ifutilized,areincludedinyour teamscostreport. 21.5BatteryRequirements Thebatteriescanonlyprovidepowertoaccessoriesonthevehicle(startermotor,brakelight,reverselight &beeper,dataacquisitions,andotherinstrumentation).Itisexpresslyprohibitedtooperatethevehicle byusingpowerfromanonboardbattery. 21.6ElectronicControls Electronic control of suspension and transmission systems is allowed. All power must come from the engineitself.Thepowercancomefromanapprovedbattery(21.4.15)ifthebatteryisbeingchargedby theonboardalternatorontheLombardiniengine. NOTE:Hybridelectricpowersystemsarespecificallyprohibited. 22.Transmission Teamsarefreetouseanytransmissionsuchthatmaximumspeedofthevehicleonaplainterrainis recommendedtobenomorethan60km/hrintopgear.

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23.TOWINGHITCHPOINT
Eachvehiclemusthavetowinghitchpointsatthefrontandrear,alongitslongitudinalcenterline.Whenin usehitchplatesmustberigidlyaffixedtothevehiclesmainframe.Adjustable/repositionablehitchplates arepermitted. Page|8 NOTE:Towinghitchpointsarerequirementsforbothcompetitioneventsandvehiclerecovery. 23.1FrontHitchPoint Thefronthitchpointmaybeeither: (a)Atubularfrontbumperstrongenoughtolifttheweightofthecarwithnopermanentdeformation andhavingamaximumoutsidediameterof25.4mm(1in)towhichacleviscanbecentrallyattached, or (b) A hitch plate complying with the requirements of 24.3, which is designed to fold or pivot, into a positionwhereitwillnotaffectanythingduringafrontendcollision. EXAMPLESOFACCEPTABLEFRONTHITCHES EXAMPLESOFFRONTHITCHESTHATARENOTACCEPTABLE Cutawaysarenotallowed

23.2RearHitchPlate Therearhitchpointmustbeaplatecomplyingwiththerequirementsof24.3. 23.3HitchPlateRequirementsMaximumandMinimum TowingplateMaximumthickness9.5mm(0.375in.) HolediameterMinimum25.4mm(1.0in.)

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RadialclearanceMaximumfromhole25.4mm(1.0in) HoletotubeMinimumclearance19.0mm(.75in) Page|9

24.VehicleIdentification
24.1NumberAssignment AssignednumbersmaybefoundontheBajaSAEIndiawebsiteintheregisteredteamlistafterfinal registration. 24.2SAEIndiaLogo SAE India logos and SAEINDI NIS Logo should be included in the reports and the design wherever appropriate.

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Section3RollCage,SystemsandDriversEquipmentRequirements
30.Introduction
The design and technical rules will be strictly enforced. It is the responsibility of each team to meet all technical requirements using sound engineering principles and construction done meeting proper fabrication procedures. Failure to do so may mean disqualification from the competition; final judgment restwiththeTechnicalInspectors.Ifyouhaveanydoubtsaboutanytechnicalrequirement,presentyour questionsbyemailtotechnical@bajasaeindia.org.TechnicalInspectorswilldotheirbesttoanswerthese questionswithintwoweeks.Pleaseincludeyourname,school,contactinformationandtherulenumberin questioninyouremail. 30.1RulesRequirementsandRestrictions 30.1.1TechnicalInspection AllBajaSAEIndiavehiclesmustpassatechnicalinspectionbeforetheyarepermittedtocompete. Onceavehiclehaspassedtechnicalinspectionitmustremaininasapprovedconditionthroughout thecompetition.Repairsmustbemadewithidenticalparts. 30.1.2RequiredModifications All installations and construction are subject to the approval of the technical inspectors, who may require modifications at their discretion. All competitors should be prepared to note these modifications during technical inspections. No modifications in the design would be allowed after theconclusionofstaticevents.Iffound,teamsshallbepenalizedwithaminimumdeductionof50 pointssubjecttothemodificationsdone. 30.1.3UnstableVehicles Anyvehicleexhibitinghandlingorothervehicledynamicsthataredeemedunstablebythetechnical inspectorswillnotbepermittedtoparticipateinthedynamicevents. Page|10

31.ROLLCAGE
31.1Objective The purpose of the roll cage is to provide a minimal threedimensional space surrounding the driver. Thecagemustbedesignedandfabricatedtopreventanyfailureofthecagesintegrity.Thecagemust belargeenoughfor: 1.Thedrivershelmettobe15.24cm(6inches)awayfromastraightedgeappliedtoanytwopointson thecockpitofthecar,excludingthedriversseatandthereardriversafetysupports. 2.Thedriverstorso,knees,shoulders,elbows,hands,andarmsmusthaveaminimumof7.62cm(3in) ofclearancefromtheenvelopecreatedbythestructureofthecar.(Thisistestedbyapplyingastraight edgedbetweenanytwopointsontheoutsideedgesofSIMandRHO,lesstherollcagepadding.)

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31.2RollCageRequirements 31.2.1ElementsoftheRollCage Theelementsoftherollcagethatmustmeetthematerialspecificationper31.5are: Page|11 RearRollHoop(RRH)Rule31.2.2 RollHoopOverheadMembers(RHO)Rule31.2.4 FrontBracingMembers(FBM)Rule31.2.7 LateralCrossMember(LC)Rules31.2.4and31.2.5 Additionalrequiredmembersmustbesteelandonlyhaveaminimumthicknessof.89mm(.035in) andaminimumoutsidediameterof2.54cm(1.0in)andareasfollows: LateralDiagonalBracing(LBD) LowerFrameSide(LFS) SideImpactMember(SIM) Fore/AftBracing(FAB) FrontLateralCrossMember(FLC) Anytubethatisusedtomountthesafetybelts Referencepoints:Seedrawingsinthissection. NOTE: When minimal dimensions are given that is to the centerline of the members, and when a clearanceforthedriverisgiven,itisdefinedbytheoutsideedgesoftherollcagememberslessthe paddinginstalled. *Allrollcagemembershavingabendradius>15.2cm(6inches)mayNOTbelongerthan71.1cm (28inches)unsupported. DEFINITIONDRIVERForthepurposesofthissection"driver"referstotheteam'slargestdriver andthe95percentilemaleproperlysuitedandwearingahelmet. 31.2.2RearRollHoop(RRH) The RRHis madeupof amaximum offoursections:twoLC athighestandlowestpointsandtwo continuous, no break vertical members. This may be one continuous hoop/tube. The drivers seat maynotintrudeintotheplane(s)oftheRRH.Theupperjunctionsinstraighttubeconstructionshall definepointsBR andBL. Ifbenttubeconstructionisused,pointsBR andBL willoccurattheupperend of each bend (See RC1). The RRH shall extend upward vertically +/ 20 degrees from points A to points B. The RRH must also be a minimum of 73.6 cm (29 in) wide at 68.6 cm (27 in) above the driversseat(checkedbyatemplate). RC1

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31.2.3RearRollHoopLateralDiagonalBracing(LDB)
Lateral bracing for the Rear Roll Hoop shall begin at a point along the vertical portion of the RRH within12.7cm(5inches)verticallyofpointBLorBRandextenddiagonallytoapointnofartherthan 12.7cm(5inches)abovepointARorALrespectively.(SeeRC2)TheverticalanglebetweentheRRH Page|12 andtheLDBmustbenolessthan20degrees.Lateralbracingmayconsistoftwoormoremembers.

RC2 31.2.4RollHoopOverheadmembers(RHO) Roll Hoop Overhead members shall join the RRH within 5.1 cm (2 inches) vertically or laterally of points B and extend generally horizontal to point C. The tubes must be continuous and no break membersfrompointBtopointCareallowed.TheRHOshallbelocatedabovethedriversseatbya minimum of 104.1 cm (41 inches). Points C should be located forward of the drivers seat by a minimumof30.5cm(12inches)asdefinedinsection31.3(SeeRC3).PointsCRandCLshallbejoined byalateralcrossmember(LC). RC3

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31.2.5LowerFrameSidemembers(LFS) LowerframesidemembersshalljointheRRHLCandextendforwardtopointsforwardofthe driversheeltoafrontlateralcrossmember.(FLC)(SeeRC4)RC4 Page|13

31.2.6SideImpactmembers(SIM) SideimpactmembersshalljointheRRHatpointsSandextendhorizontallytopointsSFforwardof thedriverstoes.(SeeRC4)TheSIMshallbebetween20.3cm(8inches)and35.6cm(14inches)(as measuredvertically)abovetheareaoftheseatincontactwiththedriver(SeeRC3). NOTE: The drivers feet must be behind the plane created by points AFR,L and SFR,L. If the tube betweenSFR, Lisbelowthedriverstoesthenanadditionalbarwillberequiredabovethedrivers toes.(Theintentofthisistoprotectthedriversfeetfromatireintrusion.) 31.2.7FrontBracingmembers(FBM) FrontbracingmembersshalljointheRHO,theSIMandtheLFS(SeeRC5).Theupperfrontbracing members(FBMUP)shouldextenddownwardandforwardandjoinpointContheRHOtotheSIMat orbehindpointsSF.TheFBMmembersmustbecontinuousandnobreakmembersfrompointCto theSIMareallowed.TheanglebetweentheFBMUPandtheverticalshouldbelessthan45degrees.

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RC5

Page|14

31.2.8RollHoopBracing(FAB) Therollhoopcanbebracedinthefrontand/orrear.Thehoopmustbebracedonbothrightand left sides. From a side view, the bracing must be triangulated, with the maximum length of any member not to exceed 101.6 cm (40 inches) between attachment points. The angles of the triangulation must be no less than 20 degrees. A bent tube cannot exceed 81.3 cm (32 inches) betweenattachmentpoints. 31.2.8.1FrontBracing If front bracing is used it must connect FBMup, LFS and the SIM. Front bracing must be attachedascloseaspossibletothetopoftherollcage(pointC). 31.2.8.2RearBracing If rear bracing is used it must be attached as close as possible to the top of the roll hoop alongtheouterperimeter.ThebracingmustbetriangulatedandconnectbacktotheRRH belowtheSIM. 31.2.9RHO/FBMGusseting If the RHO and FBM are not fabricated from a continuous tube, a gusset is required at point C. Gussetsshallbemadeofsteelplate,betriangularfromasideview,andhaveaminimumthickness of0.065.Thegussetsshallbeweldedtothesidesofthetubesandnotdirectlyintheplaneofthe tubes making up each joint (See RC6). The length of the gusset must be at least 3 times the tube diameter.

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Page|15

RC6 TheexampleontheleftshowsadesignwheregussetingisrequiredatpointC;theexampleonthe rightshowsaframewheregussetingwouldnotberequiredatpointC. 31.2.10ButtJoints All butt joints within any of the elements on the roll cage listed in section 31.2.1 (excluding the required no break members described in 31.2.2, 31.2.4 and 31.2.7) must be reinforced with a weldedsleeve.Abuttjointisdefinedasajointwheretwotubescometogethergenerallyalongthe samelineandarenotsupportedbyathirdtubeatthenode.Thesleevemustbedesignedtotightly fit on the inside on the joint being reinforced (i.e. external sleeves are not allowed), must extend into each side of the sleeved joint, a length of at least two times the diameter of the tubes being reinforced, and be made from steel at least as thick as the tubes being reinforced. In addition to meetingbasicgeometryrequirements,thesleevemustbedesignedandfabricatedtobothreinforce thejointandtodistributethestressconcentrationsoftheheataffectedzone. 31.2.11WeldConfirmationChecks Teams must conduct weld confirmation testing for each welder that welds their vehicle roll cage. Theteammustdemonstrateitsabilitytoproduceweldedjointsofaknownqualitywithmaterials, tools and procedures similar to those being used in the fabrication of the chassis. The team must conductdestructivetestingusingthefollowingrequirements: Thefollowingdefinitionswillapplytotheentiretyofrule31.2.11: AsBuiltVehicle:thevehiclepresentedattechnicalinspection RollCageElements:elementsoftherollcageasdiscussedinrule31.2.1 RollCageWelds:anyweldjoiningtwoormorerollcageelementsoroneormorerollcage elementsandoneormoregussetsasdiscussedinrule31.2.9 RollCageMaterial:tubingofthesamegeometryandalloyastherollcageelementsofthe asbuiltvehicle

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Roll Cage Welder: any person that performs welding of the roll cage welds of the as builtvehicle

Each roll cage welder must demonstrate sufficient welding skill and craftsmanship with the tools, processesandrollcagematerial.Inadditiontovisualinspectionoftheasbuiltvehicle,thenational technicalinspectorswillcollectandinspectweldingsamplesduringthetechnicalinspectionprocess Page|16 todeterminedynamicandenduranceeventcompetitioneligibility.Teamsunabletosubmitwelding samplesofadequatequality,asdefinedbelow,shallnotbeeligibletocompeteinanydynamicor enduranceevent. NOTE:Onlystudentsaretoperformweldingontheasbuiltvehicle,androllcageweldersmaybe askedtodemonstratetheirweldingskillsduringtechnicalinspection. Eachteammustsubmittwo(2)samplesforeachrollcagewelder,bothofwhichareconstructed ofrollcagematerialwhichhavebeenweldedwiththesametoolsandprocessesasthoseofthe asbuilt vehicle and which have also been subject to the following destructive testing and inspection: Sample1DestructiveTesting: Astructuremadeupofrollcagetubingweldedata90degreeangle,thelengthofeachtubetobe determinedbytheteam.<Figure1>Thisjointshouldbesubjecttodestructivetestingcausingthe jointtofailtowhichindicatessuperiorweldstrengthwithrespecttothebasematerial.(Thetesting methodislefttotheteamsdiscretion.Forexample,teamscandopulltestinginalab,orapplya momenttoonesideofthejointwhilefixingtheothersideofthejoint.)

Figure1 Sample2DestructiveInspection: Astructuremadeupofrollcagematerialthathastwotubesattachedata30degreeanglewitha length of at least 15cm from the center of the weld joint. < Figure 2 > The sample should be sectionedalongthelengthoftubetorevealadequateanduniformweldpenetration<Figure3>.

Figure2

Figure3

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Finaljudgmentofweldstrengthwithrespecttothebasematerialasitdescribedinsample1 and the adequacy and uniformity of weld penetration as described in sample 2 shall rest withthenationaltechnicalinspectors.
Weldingsamplesconstructedofmaterialotherthantherollcagematerialand/orweldedwitha process other than that of the roll cage welds of the asbuilt vehicle shall not be considered sufficientdemonstrationofweldingskillandcraftsmanshipwiththetools,processesandrollcage Page|17 material. Note:Framesthatwereconstructedinapreviousyearwillneedtohavesamplesweldedbythat welderorremovetwosectionsofthecurrentframeandperformthetestsonthesecomponents. 31.2.12FinalJudgment TherulesareconsideredaminimumbutthefinaljudgmentwillrestwiththeTechnicalInspectors.If during the event, any frame shows signs of yield and/or failure the car will be removed from competitionuntilthetechnicalinspectorsconfirmthattheframecomplieswiththerulesagain. COMMENT: Note that in all cases, especially benttube construction, technical inspectors may requireadditionalbracingiftheyfeeltherollcagedoesnotofferadequateprotection.Anytubes showingcracksanddeformationdonotcomplywiththerules. 31.3HeadRestraint A head restraint must be provided on the car to limit rearward motion of the head in case of an accident.Therestraintmusthaveaminimumareaof232sq.cm(36sqinches),andbepaddedwitha closedcellfoamthathasadensityof50100kg/m^3.Therestraintmustbeaminimumthicknessof3.8 cm (1.5 inches), and be located no more than 2.5 cm (1 inch) away from the helmet in the uncompressedstate. The headrestraintmustbesecurely mountedtothevehicle.Theheadrestraint mustmeettheaboverequirementsforalldrivers. NOTE:Iftheheadrestraintisalreadyapartoftheseat,thennoneedtoincludeaseparateone. 31.4DriverHeadClearance For driver head clearance, the roll cage must extend a minimum of 104.1 cm (41 inches) above the seatingsurfacetothebottomoftheupperrollcagetubesmeasuredverticallyusingthetemplateinRC 3.Thetemplateradiusedbottomshouldbeplacedinthejointoftheseatbaseandtheseatbackrest and positioned vertically. The template tee top describes the projection of the required clearance height forward and rearward. While the template fixes the clearance height forward, the clearance heightrearwardmustbeextendedineachdesignoverthehelmettopofaseatedandsecureddriver. Taller drivers may be accommodated by lengthening the template vertical member and raising the entire clearance height envelope abovethe104.1cm(41inches)minimum. 31.4.1HeadClearanceMinimum Inallcases,aminimumof15.2cm(6inches) vertical clearance must be provided from the

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helmettopoftheteamstallestdrivertothebottomoftherollcagetoptubesormembers. 31.5RollCage&BracingMaterials Thematerialusedfortheentirerequiredrollcagemembersspecifiedin31.2.1must,atminimum,be: Page|18 (A)Circularsteeltubingwithanoutsidediameterof2.5cm(1inch)andawallthicknessof3.05mm (.120inch)andacarboncontentofatleast0.18%. OR (B) Steel members with at least equal bending stiffness and bending strength to 1018 steel having a circularcrosssectionwitha2.54cm(1inch)outerdiameterandawallthicknessof3.05mm(.120inch). AllcalculationsshowingtheequivalencemustbeinSIunits. NOTE:Theuseofalloysteeldoesnotallowthewallthicknesstobethinnerthan1.57mm(.062inch). The bending stiffness and bending strength have to be calculated about an axis that gives the lowest value. Bending stiffness is proportional by the EI product. Bending strength is given by the value of SyI/c,(for1018steelthevaluefor;Sy=365Mpa). E=Themodulusofelasticity(205GPaforallsteels) I=Thesecondmomentofareaforthecrosssectionabouttheaxisgivingthelowestvalue Sy=Theyieldstrengthofmaterialinunitsofforceperunitarea c=Thedistancefromtheneutralaxistotheextremefiber 31.6RollCagePadding Any portion of the roll cage, roll cage bracing, side impact member or frame (excluding rear roll hoop) between the weld joints which would be contacted by the driver, must be covered by a resilient foam materialsuchasPolyethylene(pipeinsulation)withaminimumthicknessof1.2cm(.5inch). 31.7SharpEdgesonRollCageProhibited All sharp edges which might endanger the driver, crew, officials and safety staff must be eliminated by shielding and/or padding. This includes brackets, gussets, sheet stock, fastener ends, clamps, zip ties or otherfeaturesaccessibleduringservicing,judgingorcompetitionimpactorrollover. 31.8BoltedRollCages BoltedRollcagesareacceptableonlyifthefollowingrequirementsaremet: (A)Flangesortabsmustbetwice(2X)thethicknessofthetubestructures,madeofthesamematerial type.Theymustbeproperlyweldedtoeachtubingparttobejoined. (B)Flangemountsmustbetwice(2X)thediameteroftheattachedtubing,flushmated,andwithnogap betweenthefacesgreaterthan.07mm(.003)inches. (C)Tabmountsmustbedual,parallelandoneachsideofthetubingtowhichtheyarewelded,havinga welded length of at least twice (2X) the diameter of the adjoined. Tubing held by bolts must be reinforcedsuchthattheareathroughwhichtheboltpassescannotbecompressedfromtighteningor impact. 31.9DriverSeat

BAJASAEINDIAVirtualDesignRulebook
Theuseofadriverseatismandatory;cushioningorpaddingattachedtotheframeand/orfirewallwill notbeacceptedasaseat.Theseatshallbefastenedtotheframeandshallsupporttheentirebodyof thedriver(fulltorsoandhead).Theloadshallnotbetransferredtothefirewalloranyothermember exceptthosesupportingtheseat.Aclearanceof3betweenthefirewall,SideImpactMembersandthe seatmustbemaintained.Theuseofcommerciallyavailablerallyseatsishighlyrecommended.

32.COCKPIT
32.1DesignObjective Thecockpitmustbedesignedto(1)protectthedriverand(2)permiteasydriverexitinanemergency. 32.2DriverExitTime Alldriversmustbeabletoexitoneithersideofthevehiclewithinfive(5)seconds.Exittimebeginswith thedriverinthefullyseatedposition,handsindrivingpositionontheconnectedsteeringwheel,and wearingtherequireddriverequipment.Exittimewillstopwhenthedriverhasbothfeetontheground. Drivers exit time must be demonstrated by a team driver, or drivers selected by the technical inspectors. 32.3Firewall Afirewallbetweenthecockpitandtheengineandfueltankcompartmentismandatory.Itmustcoverthe area between the lower and upper lateral cross member. This firewall must be metal, at least .508 mm (.020inch)thick,andmustcompletelyseparatetheenginecompartmentandfueltankfromthecockpit. Multiplepanelsmaybeusedtoformthefirewallbutmusthavenogapsbetweenthejoints.Cutoutsinthe firewallareallowed,buttheyneed tohavegrommetsorbootsthatprevent largeamountsoffuelfrom gettingintothecockpit. 32.3.1FrontorMidengineCars If the engine is not placed in the rear of the car, then a firewall is not required to cover the area betweenthelowerandupperlateralcrossmembers.Instead,thefirewallmustmeetthefollowing standards: (A)Gastankmustbeinasealedcontainerthatpreventsfuelfromleakingintheeventofgastank failure. (B)Splashshieldsmustpreventfuelfrombeingpouredanywhereinthecockpitareaduringfueling. (Seerule35.4SpillPrevention) (C) Engine must be completely enclosed and protect the driver in the event of an engine failure. Shieldingmustmeetguardingrequirements.Thisshieldinghastobemetal;compositeswillnotbe allowed.(Seerule38.1PowertrainGuards). (D)Drivermustbeabletostillegressfromeithersideofthevehicle. (E)Theexhaustmustnotexittowardsthedriverandmustbeshielded. (F)TheremustbeaplacetomounttheTechnicalInspectionsticker(30cmx30cmor12inx12in)on the RRH. It must be located on the drivers right side above the shoulders in easy view of track workers. 32.4BodyPanels Thecockpitmustbefittedwithbodypanelsthatcovertheareabetweenthelowerframesidemember and the side impact member. No gaps can exist that are larger than 6.35 mm (0.25 inches). These

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panelsmustbemadeofplastic,fiberglass,metalorsimilarmaterial.Theymustbedesignedtoprevent debrisandforeignobjectintrusionintothedrivercompartment.Thepanelsmustbemountedsecurely totheframeusingsoundengineeringpractices(ziptiesandVelcroarenotacceptable). 32.5BellyPan Page|20 Thecockpitshouldbefittedwithabellypanovertheentirelengthofthevehicle,sothedrivercannot contactthegroundandisprotectedfromdebriswhileseatednormally.Bellypanmaterialmustbe metal,fiberglass,plastic,orsimilarmaterial.Theymustbedesignedtopreventdebrisandforeignobject intrusionintothedrivercompartment.Expandedmetal,fabric,orperforatedpanelsarenotallowed. 32.6LegandFootShielding Allsteeringorsuspensionlinksexposedinthecockpitmustbeshieldedwithmetal.Theshieldingmust preventthedriverslegsandfeetfromcomingincontact,orbecomingentangledduringoperationora failure.Nogapscanexistthatarelargerthan6.35mm(0.25inches).Thedriversfeetmustbe completelywithintherollcage. 32.7KillSwitches Eachvehiclemustbeequippedwithtwo(2)easilyaccessiblekillswitchesturningofftheignitionand theentireelectricalsystemofthecar.Brakelight,reverselightandreversealarmarerequirednottobe turnedoff. 32.7.1KillSwitchType Thekillswitchmustbeoneofthefollowing: a)01171SkiDookillswitchavailableat http://www.mfgsupply.com/m/c/01171.html?id=UxSI4Vzn b)AfterMarketWPS#270152or270124 http://www.parkeryamaha.com/index.asp?PageAction=PRODSEARCH&txtSearch=27 0152&Page=1 c)AStockPolaris#4110106 SampleMountings(Note:Thekillswitchesneedtobemountedusingtheoutercases.Iftheyare mountedusingadhesiveonthebackcovertheswitchwillfail.SeeFigure1) Note:Theweldedmetaltabs Note:Themachinedblock constrainingtheswitch. constrainingtheswitch.

Figure2 Figure1

32.7.2KillSwitchLocationsandOrientation

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(a)CockpitSwitchThecockpitswitchmustbelocatedinthefrontofthecockpitwithineasyreach ofthedriverwhenstrappedintotheseat.Theswitchmaynotbemountedonaremovablesteering wheelassembly. (b)ExternalSwitchTheexternalswitchmustbemountedonthedriversrightsideofthevehicle, Page|21 on a panel perpendicular to the firewall between RRH and Rear Bracing within the red area, and behindtheplaneofthemainrollhoop(seeFigure2).Theswitchcannotbemorethan177.8mm(7 inches)verticallybelowpointBr.Theswitchmustbewithineasyreachoftrackworkers.Theswitch mustbemountedrigidly,withnosharpedgesinthatarea. (C)Note:ThefinalauthorityofsuitabilityofanykillswitchislefttothediscretionoftheTechnical inspectors. 32.7.3KillSwitchWiring Allwiringtokillswitchesmustbesealed,protectedorsecurelyattachedtotheframetopreventthe wiresfrombeingentangledwiththedriverorobstacles.Soundengineeringpracticesmustbeused. 32.8FireExtinguisherSizeandLocation EachvehiclemusthavetwoidenticalfireextinguisherswithanISIrating.Eachmusthaveaminimum capacityof1litre.Onemustbemountedinthecockpitbelowthedrivershead,withthetophalfabove thesideimpactmemberontherightsideofthefirewallandbeeasilyaccessiblebycourseworkers.The manufacturermountsmustbeused;theymustbemetalandhaveametaldrawlatch.Thismountmust be securely fastened to the vehicle frame (RRH) and it must resist shaking loose over rough terrain, while allowing the course workers to remove it easily if necessary. The second must be brought to technical inspection with mounting accessories; it will be used as a replacement if needed. All fire extinguishers must be equipped with a 2009 manufacturer installed dial pressure gauge. The gauge mustbereadablebytheTechnicalInspectors.Fireextinguishersmustbelabeledwithschoolnameand vehiclenumber. 32.9Throttle Onlyfootoperatedthrottlecontrolsareallowed.Carshavinghandoperatedthrottlewillnotbeallowed tostartanyevent.Awideopenthrottlestopmustbemountedatthepedal.Mechanical,hydraulicor other throttle controls must be designed to return to idlestop in the event of a failure. Foot pedals mustbepositionedsoastoavoidfootentrapmentinanyposition. 32.9.1ThrottleExtensions Teams may not add any type of extension to either the control surfaces or to the driver in order to operate the vehicle. For example, drivers may not add blocks of wood to their feet so that they can reachthecontrolsofthevehicle.

33.DRIVERRESTRAINT
33.1MinimumFiveStrapSystemRequired Alldriversmustuseaminimumofafive(5)straprestraintharnessmeetingthefollowingspecifications. Afivepointsystemconsistsofa76mm(3inch)widelapbeltandapproximately76mm(3inch)wide

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shoulder harness straps, along with a fifth, antisubmarine belt (vertical strap that goes between the legs), preventing the lap belt from rising along the drivers waist. The restraint system installation is subjecttoapprovaloftheTechnicalInspector.Therestraintsystemmustbeworntightly.Nomorethan afingerwidthgapbetweenthebeltsandthedriverwillbeallowedwhenthebeltispulled. 33.1.1ReleaseMechanism Page|22 Allbeltsmustjoinwithasinglemetaltometalquickreleaselevertypebuckle.Nocamlocksystems areallowed. 33.1.2SafetyHarnessExpiration The material of all straps must be Nylon or Dacron polyester and in new or perfect condition. All driverrestraintsystemsmustmeeteitherSFISpecification16.5/16.1,orFIAspecification8853/98. Thebeltsmustbeartheappropriatedatedlabels,andonJan1stofthecompetitionyearbenomore thanthreeyearsold. 33.2ShoulderHarness Theshoulderharnessmustbetheovertheshouldertype.Onlyseparateshoulderstrapsarepermitted (i.e.Ytypeshoulderstrapsarenotallowed). 33.2.1VerticalLocation TheshoulderbeltsmustNOTbemountedabovetheshoulderlevel,andmustbeprotectedbythe firewall.Shoulderbeltsmustbenomorethan102mm(4inches)belowtheperpendicularfromthe spinetotheseatbackattheshoulderlevel. 33.2.2HorizontalLocation Theshoulderharnessmountingpointsmustbebetween178mm(7inches)and229mm(9inches) apart (see Figure below ). The straps shall not pass through anything that will cause the center distancetobelessthan178mm(7inches)fromcentertocenterofthestrap.Thestrapsshallnot passoveranythingthatcausesthemtobemorethan229mm(9inches)apartcentertocenter.

33.2.3HarnessAttachmentPoints Theshoulderharnessmustbesecurelymountedtotheprimarystructure.Shoulderbeltsmustbe loopedaroundaframetubeandhavesomethingdesignedtolimitthebeltmovement.Thebelts maygothroughthefirewallaslongasadditionalfirewallmaterialisaddedtoprotectthatportionof thebelt. 33.2.4RedirectionofHarnessWebbing

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Theredirectionofharnesswebbingtofacilitatestrongerandsimplermountingdesignsshallnotbe madebyanymeans.Specifically,webbingthatisroutedsuchthatwhentightenedwillbearaload onto the seat will not be accepted. All harness loads must pass directly onto the frame of the vehicle.(SeeFigure4) Page|23 33.3Lap&AntiSubmarineBelts The lap belt must pass around the pelvic area below the Anterior Superior Iliac Spines (the hip bones) (Figure 5). Under no condition may the lap belt be worn over the area of the intestines or abdomen. The lap belts should come through the seat at the bottom of the sides of the seat to maximize the wrap of the pelvic surface and continue in a straight line to the anchorage point. In sideview,thelapbeltmustbeatanangleofbetween45degreesand65degreestothehorizontal. Thismeansthatthecenterlineofthelapbeltattheseatbottomshouldbeapproximately76mm(3 inches) forward of the seat back to seat bottom junction (see Figure 5). To fit drivers of differing staturescorrectly,insideview,thelap/antisubmarinebeltsmustbecapableofpivotingfreelyby using either a shouldered bolt or an eye bolt attachment. Mounting lap belts by wrapping them aroundframetubesisnolongeracceptable.Thelapbeltsshouldnotberoutedoverthesidesofthe

seat. Figure5 Figure6 33.3.1SpecifiedLap&AntiSubmarineBeltsMounting Theframetabswhichacceptthelapbeltmountingtabsmustmeetthefollowingrequirements: 1)Thelapbelttabsmustbemountedindoubleshear.(SeeFigure6) 2)Theframetabsthatacceptthelapbelttabsshallbenolessthan2.3mmthick(.090). 3)Thetabsmountedtotheframetoacceptthelapbelttabsshallhavenolessthan38mm (1.5)ofweldlengthwheremountedtotheframe. 4)Thesetabsshallhave nolessthan 6.4mm (.25)ofmaterialintheradial directionfrom theedgeofthemountingboltholetotheclosestoutsideedgeofthemountingtab. 5)Wheretheharnesstabmountstotheframetabs,thelapbeltmustbecapableofpivoting freelyabouttheaxisofthemountingboltsuchthatthewebbingandtabcanalignwiththe directionoftheload.Theheightofthetabisfree,butultimatelysubjecttothejudgmentof the National Technical Inspectors. The mount should not exhibit noticeable deformation whenpulledonduringtechnicalinspection.

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33.4Belts When adjusted, no part of the belt must project beyond the cockpit area, and must not come into contactwith rotatingcomponentsofthechassis,orterrainfeatures.Looseendsofthe beltmustbe restrained, but must not be wrapped around the buckle in such a manner as to prevent proper operation.Boththelargestandsmallestdriversonateammustmeettheserestraintrequirements. Page|24 Theshoulderbeltadjusters/bucklesmustbeadjustedsothattheyaresufficientlyclearofthewebbing topermitfurthertighteningbythesafetyofficials.Thelapbeltmustbeadjustableoneachhalfofthe buckletopermitpropertighteningforalldriversofthevehicle. NOTE:Ifthebeltsdonothaveenoughadjustmentcapacitythevehiclewillbepulledfromthe competitionuntilthematteriscorrected.Carshavingseatbeltsimproperlyfittedwillnotbeallowedin theevent.Thefinaldecisioninthisregardrestswiththetechnicalinspectors. 33.5ArmRestraints Intheeventofarollover,thedriversarmsmustbekeptwithinthelimitsof thecockpit.Thecockpitisdefinedastherollcagesidesandtheplanes definedbytherollhoopoverheadmembersandthesideimpactmembers. Armrestraintsmustbesecurelyfastenedtothedriverrestraintsystem.Only commerciallyavailablearmrestraintsmeetingSFI3.3areallowed.Thearm restraintsmustindependentlyconnecttothesafetybelts. 33.5.1ArmRestraintInstallation Armrestraintsmustbeinstalledsuchthatthedrivercanreleasethemandexitthevehicle unassistedregardlessofthevehiclesposition.Thearmrestraintmustbewornbythedriveronthe forearmjustbelowtheelbow.Thedriversmustbeabletoreachthecockpitkillswitchandsteering wheelbutnotallowtheirarmstoexitthecockpit. 33.5.2ArmRestraintExpiration Thebeltsmustbeartheappropriatedatedlabels,andonJan1stofthecompetitionyearbenomore thanthreeyearsold. 33.5.3InstallationsGeneral Allinstallationsmustpreventaccidentalunfasteningfromadirectpull,rolloverorslidealongthe side.

34.BRAKINGSYSTEM
34.1FootBrake Thevehiclemusthaveatleasttwo(2)independenthydraulicbrakingsystemsthatactonallwheelsand isoperatedbyasinglefoot.Thepedalmustdirectlyactuatethemastercylinder(nocablesareallowed). ThebrakesystemmustbecapableoflockingALLFOURwheelsinastaticconditionanddynamicallyon pavementANDanunpavedsurface.

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34.2IndependentBrakeCircuits Thevehiclemustbehaveatleasttwo(2)independenthydraulicsystemssuchthatincaseofaleakor failureatanypointinthesystem,effectivebrakingpowershallbemaintainedonatleasttwowheels. Eachhydraulicsystemshallhaveitsownfluidreserveeitherthroughseparatereservoirsorbytheuse ofadammed,OEMstylereservoir. Page|25 Note:Plasticbrakelinesarenotallowed. 34.3BrakeLight Thevehiclemustbeequippedwitharedbrakelightthatismountedsuchthatthelightshinesparallel to the ground, not up at an angle. The lens must be marked with an SAE S or U rating (i.e.: SAE IPRSTM)orifitisnotratedasperSAEJ759,itmustbeequaltoorexceedthesestandards(Eg:OEM brakelightassemblies).AISandISIratedbrakelightsarealsopermitted.Thedeterminationofwhether ornotabrakelightmeetstherequiredstandardsrestswiththeTechnicalInspectors. 34.4Brake(s)Location Thebrake(s)onthedrivenaxlemustoperatethroughthefinaldrive.Inboardbrakingthroughuniversal jointsispermitted.Brakingonajackshaftorthroughanintermediatereductionstageisprohibited. 34.5CuttingBrakes Hand or feet operated cutting brakes are permitted provided section 34.1Foot Brake is also satisfied.

35.FUELSYSTEM&Fuel
35.1SystemLocation The entire fuel system must be located within the roll cage envelope such that it is protected from impact.Thetankmountingsmustbedesignedtoresistshakingloose. 35.1.1FuelTank Onlyasinglefueltankispermittedonthevehicle.Fueltanksarerestrictedtoamaximumcapacityof6 litres.Noholesareallowedinthetankeveniftheyhavebeenrepaired. 35.3FuelLines Allfuellinesmustbelocatedawayfromsharpedges,hotenginecomponentsandbeprotectedfrom chafing.Grommettingis required wherethe linespassthrough anymember ofthevehicle.Fuellines arenotallowedinthecockpit. AlllinesmustbeattachedsecurelyandbeSAEratedfuellines.Linesmustbetightfitting&notcomeoff duetojerksorvibrations.Fuelfiltersmaybeused. 35.4SpillPrevention

BAJASAEINDIAVirtualDesignRulebook
Thefueltankmustbemountedsoiffuelspillsitwillnotcomeincontactwiththedriverortheengine. Complying with this rule will require a drip pan that is at least 203.2 mm (8 inches) in diameter or equivalentareaandhavesidesofatleast38mm(1.5inches)highabovethetopedgeofthetank. 35.4.1SpillPreventionMounting Page|26 Mountingthedrippanand/orsplashshield(s)directlytothefueltankwithaconnectiononlyaround the fuel cap is insufficient and will not be allowed. Drip pans must be mounted using sound engineeringpractices.Drippansmustbegradedorinclinedsuchthatallspilledfueldrainsfromthe drippanfuelmustnotpoolanywhereinthepan. 35.4.2SpillPreventionDraining Thefuelmustdrainfromthedrippanthroughadrainlinecomposedofpipeortubingthatcarries thefueltothebottomofthecarand releasesitunderthe car.(Incompetitionsinvolvingawater hazard, the fuel must not be deposited onto floatation material, but must instead be directed aroundorthroughthefloatationbythedrainline.)Atnopointinthedrainsystem(thedrainlines andanyassociatedfittings)willtheinnerdiameterbeconstrictedtolessthan9.53mm(.375inch) this includes bolts with a hole drilled in the center used as a fitting. At least one drain line is required;multipledrainlinesareallowedforthepurposeofredundancyortoalleviatethepooling offuelindifferentpartsofthedrippan. 35.4.3SpillPreventionDrainMaterial The drains must be either fuel line material, other pipe or tubing suitable for transferring fuel. Tubing, fittings, or sealing materials that are weakened or dissolved by fuel are unsafe for this applicationandwillnotbepermitted.Iftubingisused,itishighlyrecommendedthatathreadedand barbedfittingbeusedatthepointwherethedrainlineconnectstothedrippan. 35.4.4FillerCap The standard filler caps provided with rated fuel tanks may not prevent fuel from leaking in the eventofarollover.Teamsmustensurethatthefillercapgasketdoesnotbreakdowninfuel,does not have any holes and prevents fuel from spilling. The cap must not come loose during dynamic eventsorallowfueltospillout. 35.5SplashShields Splash shields are required to prevent fuel from accidentally being poured directly on the engine or exhaust while refueling or preparing to refuel the car. The purpose of drip pan/splash shield is to contain and dispose of the fuel leaked from the tank securely to the ground, avoiding pooling or splashingorfuelonanyofthecomponentsofthevehicle.Thesplashshieldsmustbemountedinthe correctpositionatalltimes.Teamscannotmakethemadjustableorsomethingthedrivermustputinto thecorrectpositiontoensurepropercoverageduringfueling.

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Note:(BELOW)Thefollowingareexamplesofapprovedspill/splashshields:

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Note:(BELOW)Thefollowingspill/splashshieldisNOTacceptable:

36.STEERINGandSUSPENSIONSYSTEMS
36.1WheelStops All vehicles must be equipped with positive wheel locktolock stops. These stops must mounted externaltothesteeringgearandmustbelocatedatthewheelkingpins.Wheelstopsmustfunctionat fulljounce,fullreboundandallpointsinbetween.Nostrapsorcablesareallowed. 36.2TieRodProtection Thetierodsofallvehiclesmustbeprotectedfromfrontalimpact.Abumpermayberequired,atthe technicalinspectorsdiscretion,dependingonthedesignandinstallation. 36.3AdjustableTieRodEnds Adjustabletierodendsmustbeconstrainedwithajamnuttopreventloosening. 36.4Handlebarsteering Handlebaroperatedsteeringsystemisspecificallyprohibited.

37.Fasteners
Allfastenersintheengine,steering,suspension,braking(allcalipers,allmastercylindermounting,and non OEM rotors & hub systems), throttle pedal and driver restraint systems must meet the following guidelines. 37.1Fasteners AllfastenersusedinthesystemsdesignatedinSection37mustbecaptive;definedasrequiringNYLON locknuts,cotterednutsorsafetywiredbolts(inblindapplications).Lockwashersorthreadsealantdo notmeetthisrequirement.

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37.1.1LockWireProcedureDetail

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EXAMPLE:AteamusingacustomhubwithanOEMrotormustmeetthelockingrequirements,buta teamusinganOEMhubandOEMrotorwouldbeexempt. Theabovefigureillustratestheprocedureforusinglockwire: A.Aboveillustrationsassumerighthandthreads. B.Nomorethanthree(3)boltsmaybesafetiedtogether. C.Boltheadsmaybesafetiedasshownonlywhenthefemalethreadreceiveriscaptive,orthenuts meetpreviouslocknutrequirements. D. Nuts (predrilled) may be safetied in similar fashion to the illustrations with the following conditions: 1.Nutsareheattreated. 2.Nutsarefactorydrilledforusewithlockwire. E.LockwireMUSTfillaminimumof75%ofthedrilledholeprovidedfortheuseoflockwire. F. Lock wire must be aircraft quality stainless steel of .508 mm, .813mm, or 1.067mm diameter (0.020inches,0.032inches,or0.042inchesdiameter).Diameteroflockwireisdeterminedbythe threadsizeofthefastenertobesatisfied: 1.Threadsizesofandsmalleruse0.020wire. 2.Threadsizedoftouse0.032wire. 3.Threadsizes>use0.042wire. 4. The larger wire may be used in smaller bolts in cases of convenience, but smaller wire mustnotbeusedinlargerfastenersizes. 37.2FastenerGradeRequirements AllboltsusedinthesystemsdesignatedinSection37mustmeetSAEgrade5,metricgradeM8.8orAN militaryspecifications.SeeFiguresbelow. AcceptableSAEBoltGrades:

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AcceptableMilitarySpecificationBoltGrades:

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37.3ThreadExposure AllthreadedfastenersusedinthesystemsdesignatedinSection37musthaveatleasttwo(2)threads showingpastthenut. 37.4SocketHeadCapScrews Socketheadcapscrews,alsoknownasinternalwrenchingboltsorallenheadbolts,foruseinthe steering, suspension, braking, driver restraint, and throttle pedal must meet one of the following requirements: 1) The bolt head is clearly marked with the letters NAS, 12.9, or 10.9 indicating a military/aircraftorhighstrengthmetricfastener.Noothermarkingswillbeaccepted. 2) Proper documentation is supplied, which must include a purchase receipt, and manufacturersdocumentationindicatingtheboltstrength. 37.5UnmarkedFasteners/ShopManufacturedFasteners Any threaded fastener (threaded rod, eye bolts, titanium bolts, etc.) in the steering, suspension, braking,throttleanddriverrestraintsystemsthatisunmarked,ordoesnothaveanymarkingslistedin Rule37.2,ornotmanufacturedbyaNISTaccredited(orequivalent)manufacturer,willrequireoneof thefollowing: A)Apurchasereceiptandmanufacturersdocumentationindicatingthatthefastenermeets orexceedsGrade5standardsforthatsize. OR B) Equivalency calculations or test data showing that the bolt exceeds the strength for a Grade5fastenerofthesamesize. 37.6SingleShearConnections Alltierodsinsingleshearmusthaveafactorysteelsafetywasher.Balljointsaretheonlyexception. (See37.4.2)

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37.6.1TieRods Alltierodsinsingleshearmusthaveafactorysteelsafetywasher. Page|30

FactorySafetywashersareavailableatwww.chassisshop.com 37.6.2BallJoints Any commercially manufactured ball joints or rod ends with studs are allowed. Student manufacturedballjointsorrodendswithstudsarespecificallyprohibited.

38.GUARDS
38.1PowertrainGuards Allrotatingpartssuchasbelts,chains,andsprocketsthatrotateattherateofthedriveaxle(s)orfaster, mustbeshieldedtopreventinjurytothedriverorbystandersshouldthecomponentflyapartdueto centrifugal force. These guards/shields must extend around the periphery of the belt or chain. They mustbemountedwithsoundengineeringpractice,inordertoresistvibration.Theymustbeeither(a) madeofAISI1010steelatleast1.524mm(0.06inch)thickor(b)amaterialhavingequivalentenergy absorptionatruptureperunitwidthofshield.Equivalencycalculationsforthealternativematerialmust meetthefollowingrequirements:AllcalculationsmustbeshowninSIunits.Calculationsmustusethe following material properties for the 1010 steel: Yield Strength = 305 MPA, Ultimate Strength = 365 MPA,ElongationatBreak=20.0%,ModulusofElasticity=205GPA.Documentationfromthematerial manufacturer showing the Ultimate Strength, Elongation at Break, and Modulus of Elasticity of the alternative material must be provided. If a stressstrain curve for the alternative material is not providedthenitmustbeassumedthatthestressstraincurveislineartotheyieldpointandlinearfrom the yield point to the ultimate strength, where strain = elongation at break (See Figure10). If a fiber reinforced composite material is used, then a stress strain curve must be provided for worstcase tensile loading. Additionally, the curve for the composite material must be specific to the matrix and manufacturing methods used. Lastly, the minimum fiber reinforced composite material must be 3.175mm(.125inch)thick. Inordertoshowequivalencythecalculationmustshowthefollowing: AreaundercurveforAISI1010SteelxThickness<or=Areaundercurveforalternativematerialx thickness Figure10

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38.1.1SideShields Sideshieldsmustpreventfingersfromgettingcaughtinanyrotatingpart.Acompletecoveraround theengineanddrivetrainwillbeacceptable.

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38.2FactoryStockGuards Factorystockguardsmustbedemonstratedtobeequaltothosedescribedin38.1.

39.DRIVEREQUIPMENTREQUIREMENTS
39.1Helmet,NeckSupport/Collar&Goggles AlldriversmustwearawellfittingMotorCrossstylehelmetwithanintegrated(onepiececomposite shell)chin/faceguardandaSnellM2005,SA2005,BritishStandardsInstitutionBS665885typesAor A/FR.Gogglesmustincorporatetheuseoftearoffsorrolloffsystems. MOTORCROSSSTYLE
NOSTREETBIKESTYLEHELMETS

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Inadditiontothehelmet,anecksupport/collarmustbeworn.Thenecksupportmustbeafullcircle (360)andSFI3.3rated.Horseshoecollarsarenotallowed(Seefigure).Simpson,RCI,GForce,Deistor Leaf Racing Products supply neck collars that meet this requirement. Neck support must bear the

appropriatedatedlabels,andonJan1stofthecompetitionyearbenomorethanthreeyears old. Page|32

NeckSupportPermitted

NeckSupportNotPermitted

WARNING: Some MotorCross helmets have extended chin guards that will not contact the required neckcollarswhentheheadisflexedforward.Thiscombinationofhelmet/collarsystemisprohibited. Any nonspecification helmets will be confiscated until after the competition. This rule has no exceptionsanditwillbestrictlyenforced.Helmetscertifiedtootherratingsystemsmaynotbeworn.

BAJASAEINDIAVirtualDesignRulebook
Section4 CompetitionRulesandProcedures

4.1About The BAJA SAE INDIA Virtual Design Challenge is aninter collegiate competition for undergraduate engineering students. The competition aims at exposing the engineering students to real world problems based on the fields of Computer Aided Designing and Simulation of products. The students are encouraged to design, analyze and simulate a productforafictitiousfirmoutsourcingitsproductdevelopmenttothestudents.Theevent isorganizedbySocietyofAutomotiveEngineersUSAsIndianChapter,SAEINDIA.Theevent comprises of judging students on their creativity, innovations, designing capabilities and knowledge of the problem statement and its related subjects. The aim is to motivate studentstotakeupchallengingandresearchorientedprojectsinthefieldsofautomotive industry, through the application of computer aided design softwares and simulation and finiteelementanalysispackages. 4.2Objectives Everyteamshalldesign,analyzeandsimulateaprototypeofaBAJAvehicleforafictitious firm to manufacture the product at a rate of 4000 vehicles per year. The students shall design the vehicles with their knowledge of the fields of engineering using standard designingandsimulationpackages.Theyarerequiredtokeepinmindthattheproductisto bedesignedforassembly,thus,theapproachoftheprojectincludeprinciplesforDesignFor Assembly. The students are required to submit the following reports: Preliminary Design Report, indicating the basic approach followed in designing and analyzing the vehicle, an Engineering Design Report, indicating a detailed description of all the components of the BAJA Vehicle Assembly and a Project Report, with detailed modelling of the vehicle all its parametersand specifications, the thought process behindeach component and technical specifications of each component along with its drawings in both orthogonal and three dimensionalviews. The teams are required to design each component as used in BAJA Vehicles and give a detailed description of each. The components designed are thus to be assembled in the formofafunctionalBAJAVehiclewhichcouldthusbemanufacturedonafictitiousassembly line. All the teams shall give an operation sequence of assembly that would result in production of a sound BAJA vehicle. The teams would also be required to analyze the integrity of their BAJA vehicles using sound practices of CAE and simulate their vehicles using simulation packages. The teams would also be required to give a fifteen minute presentationtothemanufacturer,abouttheirdesignanditsadvantagestothecustomers aswellastheproducer.
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BAJASAEINDIAVirtualDesignRulebook 4.3Rules
TheProblemStatement Every team is required to design, analyze and simulate a prototype of a BAJA vehicle for manufacturingbyafictitiousfirmattherateof4000unitsperyear. Page|34 Theprototypeshouldbedesignedwithsoundpracticesofengineering,analyzedforsafety andsimulatedfordynamicperformanceusingstandardcomputeraideddesigning,analysis andsimulationpackagesavailable.Theparticipatingteamsmustfunctionasadesignteam, dealing into designing of various components of the vehicle. The design must include the assemblyofallthecomponentsrequiredtomakeapleasingandsatisfyingBAJAvehiclee.g, powertrain sub assemblies, steering, braking, wheel assemblies, vehicle ergonomics and aestheticsetc.Asuitableexplanationofthedesignofallthecomponentsistobegivenin theformofareporttothemanufactureralongwithabriefpresentationdealingwiththe relativeadvantagesofthedesign,itsfeasibilityetc. Thevehiclemustsatisfyalltherulesconcerningsafety,rollcageintegrityandminimumroll cage specifications as specified in the BAJA SAE ASIA 2010 Rulebook and BAJA SAEINDIA VirtualDesignChallenge2009. Theteamsmaygotoanyextentaspossibleandprovide asmuchdetailingindesignasis realistictothem. Reports CADandFEAReport ThereportmustbeinconformancewiththeSAEDesignReportformatsasavailableonthe SAE Websites and SAE India as well as BAJA SAE INDIA Websites. The report should be a maximumof8pages,includingcoverpageandexcludingonepagefullviewofdesign.The reportshoulddescribethethoughprocessbehindthedesign,thedesignprocedureandthe analysisoftheentirerollcageaswellasthesuspensionanalysisofthevehicle.Therulebook shouldincludeallparametersofthevehicledesignconcerningthesuspensionandrollcage alongwiththesuitablegraphics,graphsandtabulateddata. Points ThoughProcess Design Safety Analysis Total 100 10 30 30 30 100

BAJASAEINDIAVirtualDesignRulebook

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FEAAnalysisofRollCage RollCageAssembly

BAJASAEINDIAVirtualDesignRulebook
EngineeringDesignReport Thereportshouldgiveadetaileddescriptionofallthecomponentsofthevehicledesign.It must include all the parameters, technical details, design process and manufacturing/assembly process that must be followed to manufacture/assemble the component. It must include the design and analysis results of all components. Also, the Page|36 expected performance and parameters of the vehicle assembly shall be described in the report alongwith its analysis. The report must include graphical and tabulated data to aid thetext. AplotofthethreedimensionalA1sizeviewoftheentirevehicleassemblyincoloristobe includedwiththereport,alongwithA4sizeviewsofthecomponentsoftheassembly. Points Total 500 50 30 150 100 100 50 20 500

Design Originality Detailing Manufacturability TechnicalScrutiny DesignAnalysis Innovation

WheelAssemblyCutSection EngineAssembly

BAJASAEINDIAVirtualDesignRulebook
WheelAssembly WheelHub
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VehicleAssembly

BAJASAEINDIAVirtualDesignRulebook
VehicleSimulationReport Thereportshoulddescribethedynamicparametersofthevehiclesuchas: CorneringStability Suspension Maneuverability Rolloverstability Criticalspeedfordifferentroadconditions Eachparameterhaving70points VehicleSimulationVideo:Avideoshowingthevehiclerunningonastraightroadwitha90 degreeturnandrunningonacoursecontainingabumpandalanechangemanoeuvre.The videomustalsoindicatedriverseatedinpositionandtheforcesactingonthevehicle.The use of software packages provided to the team MSC Adams and IPG Carmaker is highly recommended to the teams. They may use any software packages as per their requirements. Points 50 400

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TotalPoints

Thereportshouldincludegraphicalaswellastabulateddatatoaidthecontextualfacts.The report should also describe the procedure for performing dynamic tests and the software used. Presentation A 15 minute presentation covering the technical aspects of the design, its feasibility to manufactureandmarketing. Points 100

TotalPoints

1100

Itissolelytheresponsibilityoftheparticipanttounderstandandapplytherulesasstated above. The participant also has the flexibility to choose the amount of detailing to be giveninthereportsaswellasthedesign. Queries,ifany,shallbeaddressedtoTechnicalCommittee,BAJASAEIndia,VirtualDesign Challenge, through email or through BAJA Virtual Design Web Section on SAE NIS Website. The rules are subject to change without any notice, any decision taken by the technical committeeshallbefinalandbinding.

BAJASAEINDIAVirtualDesignRulebook

Section5 EventDescriptionandScoring

BAJASAEINDIAVirtualDesignChallenge:October2009 29thJan2010,Day1:StaticEvents Page|39

OpeningCeremony TechnicalInspection&BrakeTest DesignEvaluation CostEvaluation Presentation GreenVehicleEvaluation

EventsScoring
StaticEvents CostReport Presentation DesignReport DesignEval. Total : : : : : 50 50 100 100 300

30thJan2010,Day2:DynamicEvents
Speed o Acceleration o MaxSpeed Traction o HillClimb o Manoeuvrability Lineup

31stJan2010,Day3:EnduranceRun Durability AwardsCeremony

DynamicEvents Acceleration : MaxSpeed : HillClimb : Manoeuvrability: Total : Endurance Durability

50 50 100 100 300

400

1st2ndFeb2010:BAJAHRMeet(Indore)

Total

1000

BAJASAEINDIAVirtualDesignRulebook
CONTACTS Page|40

BAJASAEINDIAVirtualDesignRulebook
ANNEXURE

RECOMMENDATIONS OF CODE OF CONDUCT DURING BAJA SAEINDIA 2010 Page|41 EVENT

Team members without authentic ID Cards will be liable for penalty as deemed fit by the organizers. Event timings shall be strictly adhered to, including that the organizers reserving the right to refuse re-inspection. Team may file a protest against professionally made designs with supporting evidence. The decision of the organizers in this regard will be final and binding on all parties. Teams using Unfair Means of Designing, outsourcing the project work or taking any professional help, are liable to disqualification without any notice. The registration fee under any circumstances shall not be reimbursed. Teams would be required to submit the reports and documents as on the specified dates. Teams failing to meet the deadlines would be suitable penalized. Teams are required to keep a regular check of the BAJA Virtual Design Website C/0 SAE Northern India Section for regular updates. The website shall be treated as official means of communication. The management would not be held responsible for negligence of teams in missing vital information. Teams would be required to display sponsor logos in their reports, apparel, media articles, etc, giving suitable visibility to the event sponsors. Winning teams, participating in the BAJA SAE ASIA 2010, shall treat the Virtual Event Sponsor as a prime Team Sponsor for the main event. The team would have no restriction on exploring other sponsorship options, however, the Virtual BAJA SAEINDIA Event sponsor shall be credited with appropriate visibility and benefits, failing which, the teams shall be debarred from the BAJA SAE ASIA 2010 Event. Virtual BAJA SAEINDIA Design Challenge participants except the winning teams (if participating in BAJA SAE ASIA 2010) are NOT allowed to participate in the BAJA SAE ASIA 2010 HR Meet. Any such requests would not be entertained.