Automobile

ZE
OLERANCE
Rulebook 2013
Revision # 01 5th November, 2012
Zero Tolerance Policy

100% Safe: First Time Right 100% Rulebook Compliance: Self-Certification 100% Readiness: Technical Inspection @ BAJA SAEINDIA 2013
INDEX
CONTENTS Section 1 General Information Section 2 Vehicle Requirements and Restrictions Section 3 Roll Cage, Systems and Drivers Equipment Requirements Section 4 Competition Procedures and Regulations Section 5 Technical Inspection Section 6 BAJA SAEINDIA Events Section 7 Appendices Appendix 01- Roll Cage Specification Sheet Appendix 02- Local Technical Inspection Rules Appendix 03- Code of Conduct Appendix 04- Virtual BAJA SAEINDIA Appendix 05- Design Report Format Appendix 06- Cost Report Format Appendix 07- Index Sheet for Process Cost Reference Appendix 08- Static Event Participation Sheet Appendix 09- BAJA SAEINDIA 2013 Scoring Appendix 10- BAJA SAEINDIA 2013 Awards Appendix 11- BAJA SAEINDIA 2013 Penalty Structure Appendix 12- BAJA SAEINDIA 2013 Contacts 02 03 10 26 28 31 37 37 38 39 40 42 43 45 46 47 48 49 50
www.bajasaeindia.org
Section 1 - General Information

1.1 Eligibility Vehicles
1.1.1 Student Created Undergraduate Engineering Student in India can participate in SAE BAJA 2013 event. The College / Institute needs to have at least 1 year of SAE India Collegiate membership for becoming eligible to participate in BAJA SAEINDIA. The vehicle and associated documentation must be conceived, designed and fabricated by the team members without direct /indirect involvement from professional engineers, faculty or professionals in the off-road and racing. Proof of manufacturing location will be essentially required to be furnished by the teams on-site upon being so asked for by the officials. 1.1.2 Professional Fabrication Limits 1. Only those teams, whose management gives an undertaking to allow them to use the workshop facilities, would be allowed to participate without exception. Also teams need to submit a list of facilities / equipments in operating condition with the college facilities which will be used to fabricate & assemble the vehicle as per design presented in virtual BAJA event. 2. During the actual manufacturing and fabrication process, the video clips that covers students working in college facility need to be furnished in CD-Format during the College Level Technical Inspection. 3. Extensive use of readymade subassemblies may invoke penalties. Vehicles, which have been professionally fabricated, may be penalized up to 400 points or even disqualified from the competition. The decision of the organizers committee in this regard will be final. The registration fee would NOT be returned in such case. 1.1.3 Prefabricated Subassemblies These rules do not exclude the use of prefabricated or modified sub-assemblies. Extensive use of readymade subassemblies may invoke penalties. List of pre-fabricated parts allowed are Shock Absorber, spring, Brake drum, Brake disc, Brake calipers and brake holding assembly, Master cylinder, Steering gear box, Steering column, Steering wheel, Wheel rims & Tires, Seat frame, Tie rod ends. Engine, Fuel tank & Exhaust system - complete assembly supplied from B&S to be used. All other parts need to be fabricated in house & not allowed to outsource from professional manufactures/ designers.
1.2 Top 10 Teams - Design Comparison Requirement

Teams with vehicles that finished in a top ten position in any of the previous years Baja SAE INDIA competitions are classified as having created a successful design. Such teams are required to provide a comparison of their current design with their previous years design even if the current design is entirely new. As part of the design event, judges will evaluate the comparison documentation of the top ten teams. If the judges find that the design changes are (A) not significant, (B) not supported by a detailed analysis or (C) have not been sufficiently documented, then a penalty of up to one hundred (100) points may be assessed against the design score. Modifications are defined as, but not limited to: New frame and/or roll cage design, new drive train design or arrangement (gear ratio changes are NOT considered as drive train modifications), new suspension design, driver ergonomics and controls. The redesign/design document may be in the form of either, or both, (A) posters or (B) report.
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Section 2 - Vehicle Requirements and Restrictions

2.1 Vehicle Configuration
The vehicle must have four (4) or more wheels not in a straight line. Three (3) wheeled vehicles are prohibited from the competition. The vehicle must be capable of carrying one (1) person 190.3 cm (6'3") tall weighing 113.4 kg (250 lb). 2.1.2 Maximum Vehicle Dimensions Width : 162.56 cm (64 in) at its widest point: Mandatory
Length : 274.32 cm (108 in) end to end: Recommended Vehicles exceeding the width will not be allowed to run in any event. "GO-NO-GO" device is made available by the organizers at the Technical Inspection area during the On-Site Technical Inspection to check the width (Section 5).
2.2 Required Engine

2.2.1 Briggs and Stratton Engine: 10 hp OHV Intake Since last year, the Briggs & Stratton Corporation USA has generously provided engines to the BAJA SAEINDIA teams with charges. Team pays for subsidized price and the shipping & handling charges. The teams may be asked to collect their engines from specified locations. Also, the teams are needed to arrange all the transit requirements as required by the Transportation & Insurance Authorities, at their own. All such notifications would be made available on the BAJA website, www.bajasaeindia.org. 2.2.2 Engine Eligibility Colleges/Institutes will be eligible to receive and use a new Briggs & Stratton engine in their THIRD participation only. Engines are allocated on the basis of one engine per vehicle per two seasons of participation. Example: A college/institute that receives a new Briggs & Stratton engine in year 2011 for competition season of 2012 can participate in a Baja SAEINDIA event in 2012 & 2013 with the same engine. It becomes eligible to receive a new engine only for the 2014 competition season if registered & qualified. Example: A college/institute that receives an engine in 2011, but does not compete in a Baja SAEINDIA event in 2012, is not eligible to receive an engine in 2014. It means the same engine can be used for 2013 & 2014 provided its team qualifies the criteria of selection and is registered. Similarly if the college has participated in 2012 event but not in 2013 event; then it can use the same engine for 2014 event provided its team qualifies the criteria of selection and is registered. 2.2.3 Eligible Teams - Receiving New Engines Teams that are eligible to receive a new engine must order online upon completion of registering the team for a competition. Please contact Briggs &Stratton and SAE INDIA if any team has trouble placing the engine order. Eligible teams will have to pay the cost of engine & shipping as per SAE approved rate. 2.2.3.1 Neither Briggs & Stratton nor SAE assume any responsibility for the delivery of engines. Transit Insurance can be separately born by team. 2.2.4 Purchasing of Additional Briggs & Stratton Engines Teams may purchase additional Briggs & Stratton engines directly through their local Briggs & Stratton dealer. There is no special discount or purchase price for additional engines.
2.3 Engine Requirement and Restrictions

To provide a uniform basis for the performance events, all vehicles must use the same engine: a stock of four cycles, air cooled, Briggs & Stratton OHV Intake Model. The following Briggs & Stratton engines are the only acceptable engines for the 2013 BAJA SAEINDIA competitions:
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Baja Acceptable Engines 20S232 1164 - Engine supplied in 2011 onwards. (maximum rpm to be set to 3800) 20S332 0036 - New Engine having 3800 as the maximum rpm.
NOTE: Blueprinting (reworking an engine to a manufacturers exact specifications) is considered to be modification.
2.3.1 Replacement Parts Only original equipment Briggs & Stratton replacement parts may be used. 2.3.2 Piston Rings Only standard size original Briggs & Stratton piston rings may be used. 2.3.3 Intake Ports No cleaning or removing of aluminium flashing from intake or exhaust ports may be done. 2.3.4 Valves A. Valve Clearance Any valve clearance setting between tappet and valve stem intake and exhaust may be set. B. Valve Lapping Valves may be lapped to ensure proper sealing. Intake angle must remain at 45 degrees; exhaust angle must remain at 45 degrees. 2.3.5 Shafts and Rods Camshaft, crankshaft, connecting rod and flywheel must not be altered or modified. 2.3.6 Spark Plugs Only RC12YC spark plugs must be used. Before carrying any welding activity, it is recommended that the spark plug cable is removed and battery terminal cables are disconnected. This will prevent burning of wiring harness and HT Coil. 2.3.7 Armature Any armature air gap setting is allowed. No slotting or elongating of armature mounting holes to increase or retard ignition timing. 2.3.8 Flywheel Rotation No flywheel rotation to advance or retard timing is permissible. 2.3.9 Carburettor A. Carburettor This is a fixed carburettor, re-jetting of the carburetor is prohibited. B. Idle Speed Any idle speed adjustment is allowed, Briggs & Stratton recommends 1750 100 rpm. C. Carburettor Float Carburettor float is non-adjustable and may not be re-adjusted. D. Carburettor Venturi Modification of carburettor venturi is prohibited. 2.3.10 Air Cleaner The air intake system should use a Filter from Briggs and Stratton recommended source. The teams may be required to submit proof of purchase. The filter should be located as close as possible to the engine. The air intake may be relocated, but Briggs & Stratton parts must be used to relocate the air filter: remote kits, 695329 choke shaft and 699960 - air cleaner base (metal). The supplied air hose may be shortened to a minimum of 152 mm (6.0 in). No other type of hose will be allowed. A team may also add additional pre-filters (part number: 491435S) to the top of the air intake. These parts must be included on the cost report. Any changes made to the air filter will have to pass Briggs & Stratton inspection.
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NOTE: Relocation of the air cleaner may decrease engine performance. Any damage on account of failure to comply with the instructions would have to be borne by the team. The complete air intake system shall be located so that its extremities lie at least 100 mm within the perimeter of the vehicle. The decision of the Head of the Technical Committee of Baja SAEINDIA / Briggs and Stratton personnel in this regard will be final and binding to all. This is in the interest of safety.
A fresh air cleaner element & paper filter are required during On-site Technical Inspection-Engine at BAJA SAEINDIA 2013. 2.3.11 Exhaust System A. Muffler & Exhaust system Since B&S Engine is supplied with pre mounted exhaust system, there is no need to change the mounting. This year GO GREEN implementation on vehicle is not considered, hence CAT-CON or any other emission related changes are not required to be worked out and/or demonstrated. Regarding GO GREEN Award, concept model & system need to be separately worked out for presentation during the event. Details for GO GREEN Award will be separately put on the official BAJA SAEINDIA 2013 website. B. Exhaust System Durability Required The exhaust pipe and muffler must be completely intact and operational throughout the event, and shall be grounds for penalty or disqualification if not intact at the end of any event, including endurance event. The decision of the representatives of the engine manufacturer and/or the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all. C. Exhaust system complete The complete exhaust system exhaust system shall be located such that its extremities lie at least 100 mm within the perimeter of the vehicle. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all. This is in the interest of safety. D. Exhaust system painting This is recommended but not compulsory. 2.3.12 Starter The Recoil Starter Rope may be extended to accommodate the driver starting the engine while being seated. Electric start is not acceptable in any case even if it is from B&S standard parts. 2.3.13 Alternator The engine is not configured for fitment with an external alternator to generate electrical energy. Hence it is not permitted. 2.3.14 Engine Governor Each engine is equipped with a governor. Each governor will be set at the competition to a 3800 rpm or maximum speed. Random inspection of the governor may be conducted at any time. Any attempt to defeat the engine governor so as to increase the engine speed grounds for immediate disqualification.
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GOVERNOR SETTING: NOT TO EXCEED 3800 RPM. The governor operation must remain free of obstructions at all times. Governor area must be shielded from debris. The stock configuration of fuel tank mounted to the engine is acceptable for debris management. However, if the fuel tank is to be remote mounted, a debris shield covering the exposed governor area is required. Briggs & Stratton part number 697326 Control Cover may be used or some other part with equivalent features.
NOTE: The governor spring must be placed in hole # 6. The top 10 vehicles in the Endurance Event will be checked for the same.
2.3.15 Hybrid Electric Power Systems Hybrid electric power systems are specifically prohibited. 2.3.16 Energy Storage Devices Used for Propulsion Hydraulic accumulators are the only type of stored energy device that may be incorporated into the vehicle for propulsion purposes. If employed, hydraulic accumulators must be at zero energy at the start of each event. Hydraulic power systems must be properly shielded and documentation of the shielding made available for review.
2.4 Engine Use Restriction

Briggs & Stratton generously provides engines to the teams for the exclusive purpose of use on their BAJA SAEINIDA vehicle. If, for any reason, a team receives an engine and at a later date decides not to participate, it must, at its own expense, return the engine to SAE or Briggs & Stratton.
2.5 Battery Requirements

& beeper, data acquisitions, safety items and other instrumentation). It is expressly prohibited to operate the vehicle by using power from an on-board battery. The mounting of battery must prevent the battery from coming loose during a roll over & must be enclosed from the exhaust and the fuel system. There should not be any positive contact with the exhaust unit of the fuel system. The battery must be safely placed & concealed. Failing this, the technical inspectors may debar the team from the dynamic events. Recommended Battery: 12 V, 44 Ah 2.5.1 Electronic Controls Electronic control of suspension and transmission systems is allowed. The power can be from the approved battery.
2.6 Component Failure

In the event of a major component failure during the course of the event, any modifications must be approved by the Technical Inspectors prior to the vehicle returning to the competition. Teams without the approval may be penalized as per the decision of the Head of Baja Technical Committee.
2.7 Engine Use Restriction

The B&S staff on-site is empowered to make final decisions regarding the condition and set-up of all engines. NOTE from B&S: B&S will Provide support, however, if it is observed that the damages to the engine are caused due to teams negligence in handling/ installing/ running the engine as per the specified directions given by B&S. or as specified in the manual supplied by B&S, the teams may be charged for the repairs or for procuring a new engine in place of the damaged engine. No components/spares shall be installed without consulting B&S authorities or the organizer committee member. Queries regarding the engine and related peripherals may be addressed to engine.baja@bajasaeindia.org.
2.8 Transmission
Teams are free to use any transmission, such that maximum speed of the vehicle on a plain terrain is recommended to be no more than 60 km/hr in top gear. Continuously Variable Transmissions (CVT) are also permitted with appropriate shielding as in Sec 3.19.1.Teams can plan to install reverse gear for reverse drive of vehicle.
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Teams need to safely install gear shifting cables; lever and shifting mechanism are installed at such locations which will not be hindrance for driver and his safety. The adapter for Engine & Transmission is to be designed and installed by students as per the type of transmission used. Engine drive / output shaft side details are available on BAJA SAEINDIA official website. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all.
2.9 Reverse Light and Alarm

It is mandatory that each vehicle should be equipped with a reverse light (Amber color, visible at a minimum distance of 10 meters from vehicle). Reverse alarm is not mandatory however it is recommended to be installed for safety reason which shall operate when the reverse gear is engaged.
2.10 Towing Hitch Point

Each vehicle must have towing hitch points at the front and rear, along its longitudinal centerline. 2.10.1 Front Hitch Point The front hitch point may be either: (a) (b) A tubular front bumper strong enough to lift the weight of the car with no permanent deformation and having a maximum outside diameter of 25.4 mm (1 in.) to which a clevis can be centrally attached, or A hitch plate complying with the requirements of Section 2.10.2, which is designed to fold or pivot, into a position where it will not affect anything during a front-end collision.
EXAMPLES OF ACCEPTABLE FRONT HITCH POINT
EXAMPLES OF NOT ACCEPTABLE HITCH POINT

Figure 1
Cut a ways are not allowed

Figure 2
Do Not Pivot
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2.10.2 Rear Hitch Plate Requirements Maximum and Minimum Towing plate Maximum thickness - 9.5 mm (0.375 in.) Hole diameter Minimum - 25.4 mm (1 in.) Radial clearance Maximum from hole - 25.4 mm (1 in.) Hole to tube Minimum clearance 19.0 mm (0.75 in.)
2.11 Vehicle Identification
Figure 3
Each team is responsible to display its vehicles number as either a silhouette or stencil form cutout at least 203 mm (8 in.) high & have a minimum line width of 2.54 cm (1 in.). This must form a pyramid shaped structure situated at the top of the vehicle. Assigned numbers may be found on the Baja SAE India website in the registered team list after final registration. The numbers must be clearly visible from both the front and rear sides of the vehicle. If a vehicles numbers are illegible then it may not be scored. Painted-on numbers or stencils/decals mounted flush to a body panel will not be allowed. Only stickers are allowed. The numbers must allow mud to shed during dynamic events, cars with numbers that are hard to read, missing, damaged or obscured may not be scored and may be black flagged. Vehicle Number - Body All vehicles must display their assigned number in block numerals on the front and both sides. These numbers must be at least 20.3 cm (4 in.) high, have a minimum line width of 2.54 cm (1 in.) and must strongly contrast with the background vehicle color.
Figure 4
2.11.1 Number Location These numbers must be affixed to the upper sides of the frame between the rear support and the rear roll hoop. The numbers must be in the vertical plane of the side of the car and also on the rear of the vehicle on the plane containing the upper FABs (Fore/ Aft bracing) NOTE: Refer to Figure 4 for more clarity. 2.11.2 College Name All vehicles must display their college name or initials, in roman characters, on each side in characters at least 2.5 cm (1 in.) high and 1 cm (0.4 in.) wide. 2.11.3 Event Sponsor Logos Sponsors logos must be displayed in a prominent space on each side of the vehicle (as per Figure 4). These will be distributed during registration at the event site. SAE India logos would be provided to the teams at the event site only. These are required to be pasted on both sides of the vehicle, at the centre of the side panels, and above the head of the driver, at the firewall (Figure 4). Teams may display advertising from their vehicles sponsors, provided it is in good taste and does not conflict with the vehicles number.
NOTE: Please refer to the paint and logo placement guidelines as annexed.
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2.12 Transponders
Figure 5 - Transponder
2.12.1 One transponder will be provided to each team during the endurance event at no cost for the event purpose. This is essential to use for endurance event for counting the laps during endurance run. The team caption is responsible for returning it, at the end of endurance run. It is the team captains responsibility to design a secure and safe mounting for the transponder at given location and acceptable method.
Figure 6
Mounting bracket of sheet metal box of size 55 x 45 x 20mm to be attached/ weld from outside of SIM on Right side of vehicle.
2.12.2 Transponder Mounting Each transponder as shown (Figure 5) is supplied on the last day of endurance event. However Teams are advised to make a provision of box weld / attached of sheet metal /fiber /plastic of size 55 x 45 x 20 mm on Side Impact Member of frame. Attaching the bracket with M4/M6 size with Pan / Flat head bolts with lock nuts or fix by strong wire is suggested. The transponder mounting requirements are: The provision for fitment of transponder is essential to fix it in right position so that it does not come out due to bumps or shaking of vehicle. Its essential to ensure the signal transmitted by transponder is read by timing system, so that the purpose of counting laps is not be defeated. (1) Orientation - The bracket must be mounted vertical to the frame. The transponder must be mounted on the drivers right side forward of the seat (2) (3) Location no more than 61 cm (24 in.) above the track. Unobstructed No obstruction between the antenna on the bottom of the transponder and the ground. Metal and carbon fiber may interrupt the transponder signal. The signal will normally transmit through fiberglass and plastic hence it is advice to use it. However if sheet metal box is used it should have cut out 10.2mm (0.4 in.) diameter opening from sensor side. Protection Mount the transponder where it will be protected from obstacles.
(4)
2.12.3 Transponder Black Flag If, for any reason, a cars transponder signal is not being received by the timing system, then the car will be black flagged for transponder repair, relocation or replacement. Team & driver need to be carefully observing such flags & must respond promptly.
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Section 3 - Roll Cage, Systems and Drivers Equipment Requirements

3.1 Modifications at Last Minute Once the Technical Inspection check is approved and stickers are issued for the vehicle indicating cleared for Static & Dynamic event, teams need to participate with the vehicle without any modifications/ improvements. In case of any teams found doing changes/ modification in system will be disqualified/ penalized for such last minute changes in vehicle. All installations and construction are required to be intact as in approved condition by technical inspector. No modifications in the design would be allowed after the conclusion of static events. Teams may be penalized with a minimum deduction of 50 to the maximum of 200 points subject to the modifications done on vehicle. 3.2 Unstable Vehicle Any vehicle exhibiting handling or other vehicle dynamics that are deemed unstable by the technical inspectors will not be permitted to participate in the dynamic events. The decision of the Head of the Technical Committee of Baja SAEINDIA in this regard will be final and binding to all. This is in the interest of safety of all teams.
3.3 Roll Cage

3.3.1 Objective The purpose of the roll cage is to provide a minimal space surrounding the driver and to support all subsystems. The cage must be designed and fabricated to prevent any failure of the cages integrity. It should be large enough for accommodating hefty & tallest member participating in a team in driving position. 3.3.2 Lateral Space The minimum space is based on clearance between the driver and straight edge applied to any two points on the roll cage. 1. 2. The drivers helmet to be 152 mm (6 in.) clearance to the top of roll cage. The drivers shoulders, torso, hips, thighs, knees, arms elbows, and hands, shall have a minimum of 76 mm (3 in.) of clearance from the envelope created by the structure of the car.
NOTE : When minimal dimensions are given that is to the centerline of the members, and when a clearance for the driver is given, it is defined by the outside edges of the roll cage members less the padding installed.
DRIVER DEFINITION - For the purposes of this section "driver" refers to the team's largest driver and the 95percentile male properly suited and wearing a helmet. 3.3.3 Roll Cage Structure 3.3.3.1 Elements of Roll Cage Roll cage must be space frame of tubular steel. The required members of roll cage are A. Primary members
NOTE: The primary members must conform to Section 3.6.1. [Circular steel tubing with an outside diameter of 25mm (1 in.) and a wall thickness of 3 mm (0.120 in.) and a carbon content of at least 0.18%.]
B.
Rear Roll Hoop (RRH) Rear Hoop Overhead Members (RHO) Front Bracing Member (FBM) Lateral Cross Member (LC) Front Lateral Cross Member (FLC) Secondary Members Lateral Diagonal Bracing (LBD) Lower Frame side (LFS)
NOTE: Secondary members must be steel tube having minimum wall thickness of 0.89 mm (0.035 in.) and min outside diameter 25.4mm (1 in.).
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Side Impact Member (SIM) Fore / Aft Bracing (FAB) Under seat Member (USM) All other required cross members. Any tube used to mount safety belts. Roll cage members which are not straight must not extend longer than 711 mm (28 in.) between supports. Small bend radii (<152 mm/ 6 in.) at a supported end of a member are expected, and are not considered to make a member not-straight. The minor angle between the two ends of a not-straight tube must not exceed 30.
NOTE: Required dimensions between roll cage members are defined by measurements between member centerlines, except where noted.
All Roll cage members having a bend radius > 15.2 cm (6 in.) may NOT be longer than 71.1cm (28 in.) unsupported. 3.3.3.2 Rear Roll Hoop (RRH) The RRH is a structural panel behind the drivers back, and defines the back side of the roll cage. The driver and seat must be entirely forward of this panel. The RRH is substantially vertical, but may incline by up to 20 deg from vertical from points A to points B towards rear side in parallel with seat backrest. The RRH is made up of a maximum of four sections: two LCs at highest and lowest points and two continuous, no break vertical members This may be one continuous hoop/tube. The drivers seat may not intrude into the plane(s) of the RRH. The RRH must be a minimum of 73.6 cm (29 in.) wide at 68.6 cm (27 in.) above the drivers seat (H-point of driver).
Figure 7 NOTE: The RRH will have an additional member for seat belt mounting. (Section 3.12.3)
3.3.3.3 Rear Roll Hoop Lateral Diagonal Bracing (LDB) The RRH must be diagonally braced. The diagonal brace(s) must extend from one RRH vertical member to the other. The top and bottom intersections of the LDB members and the RRH vertical members shall begin at a point along the vertical portion of the RRH within 12.7 cm (5 in.) vertically of point BR or BL and extend diagonally to a point no farther than 12.7 cm (5 in.) above point AR or AL respectively. (Figure 8) The angle between LDB members and RRH vertical members must be greater than or equal to 20 deg. Lateral bracing may consist of more than one member.
Figure 8
3.3.3.4 Roll Hoop Overhead members (RHO) The forward ends of RHO members (intersection with the LC) define points CR and CL (Figure 10). Points CR and CL must be at least 30.5 cm (12 in.) forward of a point, in the vehicles elevation view, defined by the intersection of the RHO member and a vertical line rising from the after end of the seat bottom. This point on the seat is defined by the seat bottom intersection with a 10.1 cm (4 in.) radius circle which touches the seat bottom and the seat back. The top edge of the template is exactly horizontal with respect to gravity.
Figure 9
Figure 10 11
3.3.3.5 Lower Frame Side members (LFS) Lower frame side members defines the lower right & left edges of roll cage & joins RRH LC and the points forward of the drivers heel to a front lateral cross member (FLC). (Figure 10) 3.3.3.6 Side Impact members (SIM) The two Side Impact Members define a horizontal mid-plane within the roll cage. These members are joined to the RRH at points S and extend horizontally to points SF forward of the drivers toes (Figure 10). The SIM must be between 20.3 cm (8 in.) and 35.6 cm (14 in.) (as measured vertically) above the area of the seat in contact with the driver (Figure 9).
NOTE: Every drivers feet must be behind the plane created by points AF RL and SF RL. If the LC between SF R, L is below the drivers toes then an additional LC must run between the FBM members above the drivers toes. (The intention of this is to protect the drivers feet from a tire intrusion).
3.3.3.7 Under Seat Member (USM) The two LFS members must be joined by the Under Seat Members. The USM must pass directly below the driver where the template in RC3 intersects the seat bottom. The USM must be positioned in such a way to prevent the driver from passing through the plane of the LFS in the event of seat failure. 3.3.3.8 Front Bracing members (FBM) Front bracing members (continuous, with no break) must join RHO, SIM and LFS (Figure 11). The upper Front Bracing Members (FBM UP) must join points C on the RHO to the SIM at or behind points SF. The lower Front Bracing Members (FBM LOW) must join points AF to points SF. The FBM must be continuous tubes. The angle between the FBMUP and the vertical must be less than or equal to 45 degrees.
Figure11
3.3.3.9 Roll Hoop Bracing (FAB) The hoop must be braced on both right and left sides. From a side view, the bracing must be triangulated, with the maximum length of 101.6 cm (40 in.) between attachment points. The angles of the triangulation must be minimum 20 degrees. A bent tube cannot exceed 81.3 cm (32 in.) between attachment points. 3.3.3.9.1 Front Bracing If front bracing is used it must connect FBM up, LFS and the SIM. Front bracing must be attached as close as possible to the top of the roll cage (point C). 3.3.3.9.2 Rear Bracing If rear bracing is used it must be attached as close as possible to the top of the roll hoop along the outer perimeter. The bracing must be triangulated and connect back to the RRH below the SIM. 3.3.4 RHO/FBM Gusseting If the RHO and FBM are not fabricated from a continuous tube, a gusset is required at point C. Gussets shall be made of steel plate, be triangular from a side view, have length at least 3 times the tube diameter and have a minimum thickness of 3.2mm (0.13 in.) The gussets shall be welded to the sides of the tubes and not directly in the plane of the tubes making up each joint (Figure 12).
Figure12
Left - gusseting is required at point C; Right - where gusseting would not be required at point C.
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3.3.5 Butt Joints All butt joints within any of the elements on the roll cage listed in section 3.3.3.1 (excluding the required no break members described in 3.3.3.2, 3.3.3.4 and 3.3.3.8) must be reinforced with a welded sleeve. The sleeve must be designed to tightly 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. 3.3.6 Weld Confirmation Checks Teams must conduct weld confirmation testing for each welder that welds their vehicle roll cage.
NOTE: Only students are to perform welding on the as-built vehicle i.e. the vehicle presented at technical inspection and roll cage welders i.e. any person that performs welding of the roll cage welds of the as-built vehicle may be asked to demonstrate their welding skills during technical inspection at college level.
Each team must submit two (2) samples for each roll cage welder, both of which are constructed of roll cage material which have been welded with the same tools and processes as those of the as-built vehicle and which have also been subject to the following destructive testing and inspection: Sample 1 Destructive Testing: A structure made up of roll cage tubing welded at a 90 degree angle, the length of each tube to be determined by the team, should be subject to destructive testing causing the joint to fail to which indicates superior weld strength with respect to the base material. (Figure13a) Sample 2 Destructive Inspection: A structure made up of roll cage material that has two tubes attached at a 30 degree angle with a length of at least 15cm from the center of the weld joint (Figure 13b). The sample should be sectioned along the length of tube to reveal adequate and uniform weld penetration (Figure 13c).
Figure 13
Final judgment of weld strength with respect to the base material as it described in Sample 1 and the adequacy and uniformity of weld penetration as described in Sample 2 shall rest with the national technical inspectors. Teams unable to submit welding samples of adequate quality, as defined below, shall not be eligible to compete in any dynamic or endurance event. Welding samples constructed of material other than the roll cage material and / or welded with a process other than that of the roll cage welds of the as-built vehicle shall not be considered sufficient demonstration of welding skill and craftsmanship with the tools, processes and roll cage material.
Note: Frames that were constructed in a previous year will need to have samples welded by that welder or remove two sections of the current frame and perform the tests on these components.
All the teams need to take 10 min video shoot while 1) fabricating frame & 2) assembly of complete vehicle with the college premise & covering other facilities of college & team student working on vehicle. This must be submitted during Technical Inspection at college level. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all.
3.4 Head Restraint

A head restraint must be provided on the driver seat / fire wall to limit rearward motion of the head in case of an accident. Minimum area=232 sq. cm (36 sq in.), padded with a closed cell foam (density of 50 -100 kg/m^3).Minimum
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thickness=3.8 cm (1.5 in.), located no more than 2.5 cm (1 in.) away from the helmet in the uncompressed state. The head restraint must meet the above requirements for all drivers. NOTE: If the head restraint is already a part of the seat, then no need to include a separate one.
3.5 Driver Head Clearance

Minimum driver head clearance=104.1 cm (41 in.), above the seating surface to the bottom of the upper roll cage tubes measured vertically using the template in Figure 14. Minimum vertical clearance=15.2 cm (6 in.) must be provided from the helmet top of the teams tallest driver to the bottom of the roll cage top tubes or members.
Figure 14
3.6 Roll Cage & Bracing Materials

3.6.1 The material used for the Primary Roll Cage Members must be: A. Circular steel tubing with an outside diameter of 25mm (1 in.) and a wall thickness of 3 mm (0.120 in.) and a carbon content of at least 0.18%. Or B. A steel tube with bending stiffness and bending strength exceeding that of circular steel tubing with an outside diameter of 25mm (1 in.) and a wall thickness of 3 mm (0.120 in.) and a carbon content of 0.18%. The wall thickness must be at least 1.57 mm (0.062 in.), regardless of material or section size. Calculations must be presented at Technical Inspection which proves sufficient bending stiffness and bending strength. All calculations must be in SI units. Invoices or other evidence of the properties of the roll cage materials must be attached to the calculations. Calculations must be performed using three significant figures to the nominal tube sizes as specified by the invoice. 3.6.2 The bending stiffness and bending strength must be calculated about a neutral axis that gives the minimum values. Bending stiffness is considered to be proportional to the product EI where: E :Modulus of elasticity (205 GPa for all steels) I :Second moment of area for the structural cross section Bending strength is given by: (SyI )/C where: Sy :Yield strength (365 MPa for 1018 steel) C :Distance from neutral axis to extreme fiber
3.7 Roll Cage Specification Sheet:

Each team must present a completed BAJA SAEINDIA Roll Cage Specification Sheet (Sec 7, Appendix 1) at Technical Inspection. While procuring tube one should get copy of tube specification and also ensure this is certified from local laboratory. Both copies must be presented during Tech Inspection at College level and Final Check at event site.
NOTE: Latest Material Specification Check Report is essential for used material.
3.8 Roll Cage Padding

Any portion of the roll cage, which would be contacted by the driver, must be covered by a resilient foam material such as Polyethylene (pipe insulation) with a minimum thickness of 1.2 cm (0.5 in.). Any vehicle not meeting this requirement shall not be allowed to take part in any events. Inspectors shall measure this dimension as per the Technical Inspection Sheet. 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 other features accessible during servicing, judging or competition impact or roll over.
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3.9 Bolted Roll Cages

Bolted Roll cages are acceptable only if the following requirements are met: (A) Flanges or tabs must be twice (2X) the thickness of the tube structures, made of the same material type. They must be properly welded to each tubing part to be joined. (B) Flange mounts must be twice (2X) the diameter of the attached tubing, flush mated, and with no gap between the faces greater than 0.07 mm (0.003 in.). (C) Tab mounts must be dual, parallel and on each side of the tubing to which they are welded, having a welded length of at least twice (2X) the diameter of the adjoined. Tubing held by bolts must be reinforced such that the area through which the bolt passes cannot be compressed from tightening or impact.
3.10 Cockpit
3.10 1 Drivers seat The use of a driver seat is mandatory; cushioning or padding attached to the frame and/or firewall will not be accepted as a seat. The seat shall be fastened to the frame and shall support the entire body of the driver (full torso and head). The load shall not be transferred to the firewall or any other member except those supporting the seat clearance of 75 mm (3in.) between the firewall, Side Impact Members and the seat must be maintained. The use of commercially available rally seats is highly recommended. Recliner Seats are not allowed. Driver Exit Time All drivers must be able to exit on either side of the vehicle within five (5) seconds. Exit time begins with the driver in the fully seated position, hands in driving position on the connected steering wheel, and wearing the required driver equipment. Exit time will stop when the driver has both feet on the ground. 3.10.2 Firewall A firewall between the cockpit and the engine and fuel tank compartment is mandatory. The firewall is recommended to be behind the RRH. It must cover the area between the lower and upper lateral cross member. This firewall must be metal, at least 0.508 mm (0.020 in.) thick. Cutouts in the firewall are allowed, but they need to have grommets or boots that prevent large amounts of fuel from getting into the cockpit. Front or Mid-engine Cars If the engine is not placed in the rear of the vehicle, then a firewall is not required to cover the area between the RRH lateral cross members. Instead, the firewall must meet the following standards: If the engine is not placed in the rear of the vehicle, then a firewall is not required to cover the area between the RRH lateral cross members. Instead, the firewall must meet the following standards: (A) Fuel tank must be in a sealed container that prevents fuel from leaking in the event of fuel tank failure. (B) Splash shields/ Drip Pan must prevent fuel from being poured anywhere in the cockpit area during fuelling. (See rule 3.16.3 Spill Prevention) (C) Engine must be completely enclosed and protect the driver in the event of an engine failure. Shielding must meet guarding requirements. This shielding must be made of metal. . (See rule 3.19.1 Power train Guards). (D) All engine compartment venting must be directed away from driver area. (E) Driver must be able to still egress from either side of the vehicle. (F) The exhaust must not exit towards the driver and must be shielded. (G) There must be a place to mount the Technical Inspection sticker (30cm x 30cm or 12 in x 12 in) on the RRH. It must be located on the drivers right side above the shoulders in easy view of track workers.
Note: Engine enclosures must prevent fuel from spilling onto driver area during any vehicle upset.
Body Panels The cockpit must be fitted with body panels that cover the area between the lower frame side member and the side impact member. No gaps can exist that are larger than 6.35 mm (0.25 in.). These panels must be made of plastic, fiberglass, metal or similar material. They must be designed to prevent debris and foreign object intrusion into the driver compartment. The panels must be mounted securely to the frame using sound engineering practices
NOTE: Zip ties and Velcro are not acceptable.
3.10.3 Belly Pan and Leg/ Foot Shielding The cockpit should be fitted with a belly pan (minimum length being the cockpit), so the driver cannot
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contact the ground and is protected from debris while seated normally. All steering or suspension links exposed in the cockpit must be shielded with metal. The shielding must prevent the drivers legs and feet (completely within the roll cage), from coming in contact, or becoming entangled during operation or a failure. No gaps can exist that are larger than 6.35 mm (0.25 in.). (completely within the roll cage), from coming in contact, or becoming entangled during operation or a failure. No gaps can exist that are larger than 6.35 mm (0.25 inches). 3.10.4 Kill Switches Each vehicle must be equipped with two (2) easily accessible kill switches to push off the ignition and the entire electrical system of the car. However Brake light, Reverse light and Reverse Alarm should not be switched off by use of Kill switch. Kill switch which operates by Push-to-Off is only allowed to use on Baja Vehicle. Rotary switches or Pull-to-Off type switches are not allowed. 3.10.4.1 Kill Switch Type The kill switch must be one of the following types: a) 01-171 Ski-Doo kill switch available at http://www.mfgsupply.com/m/c/01-171.html?id=UxSI4Vzn b) AfterMarketWPS#27-0152 or 27-0124 http://www.parkeryamaha.com/index.asp?PageAction=PRODSEARCH&txtSearch=27-0152&Page=1 c) A Stock Polaris # 4110106 Sample Mountings
NOTE: The kill switches need to be mounted (bolted or riveted) using the outer cases. If they are mounted using adhesive on the back cover the switch will fail constraining the switch.
Fig. 15 - The welded metal tabs Note: The welded metal tabsconstraining the switch. Figure 15
Fig. 16 - The machined block Note: The machined block constraining the switch. Figure 16
Fig. 17 - Mounting illustration in vehicle
Fig. 18 - Schematic for Kill Switch Mounting
The Kill switch is primarily safety device to stop engine in case of fire or any type of accident. The team and track volunteer at event will be required to follow unique convention of stopping engine in such case only by following up Push-To-Off. Hence any deviation from the kill switch specification will not pass technical inspection & team will be disqualified. (With ISI mark) 3.10.4.2 Kill Switch Locations and Orientation (a) Cockpit Switch In the front of the cockpit within easy reach of the driver when strapped into the seat. The switch may not be mounted on a removable steering wheel assembly. (b) External Switch The external switch must be mounted on the drivers right side of the vehicle, on a panel perpendicular to the firewall between RRH and Rear Bracing within the red area, and behind the plane of the main roll hoop (Figure 17 & 18). The switch cannot be more than 177.8 mm (7 in.) vertically below point BR. The switch must be within easy reach of track workers.
NOTE: In case of either/ both switches in close condition, engine should not get start. The final authority of suitability of any other kill switch is left to the discretion of the Technical inspectors.
3.10.5 Fire Extinguisher Size and Location Each vehicle must have two identical fire extinguishers (minimum capacity = 1 liter) with an ISI rating. One must be mounted in the cockpit below the drivers head, with the top half above the side impact member on the right side
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of the firewall and be easily accessible by course workers. The second must be brought to technical inspection with mounting accessories. All fire extinguishers must be equipped with a 2012 manufacturer installed with dial pressure gauge. The gauge must be readable by the Technical Inspectors. Fire extinguishers must be labeled with College name and vehicle number. 3.10.6 Throttle Only foot operated throttle controls are allowed. Cars having hand operated throttle will not be allowed to start any event. A wide-open throttle stop must be mounted at the pedal. 3.10.6.1 Throttle Extensions Teams may not add any type of extension (e.g. blocks of wood) to either the control surfaces or to the driver in order to operate the vehicle.
3.11 Driver Restraint

3.11.1 Minimum Four Strap System Required All drivers must use a minimum of a four (4) strap restraint harness. However, it is strongly recommended to use a 5 point restraint harness meeting the following specifications. A five-point system consists of a 76 mm (3 in.) wide lap belt and approximately 76 mm (3 in.) wide shoulder harness straps, along with a fifth (anti-submarine) belt must be worn between the legs, preventing the lap belt from riding up along the drivers torso. The restraint system installation is subject to approval of the Technical Inspector. No more than a finger width gap between the belts and the driver will be allowed when the belt is pulled. 3.11.2 Release Mechanism All belts must join with a single metal-to-metal quick release lever type buckle. No cam-lock systems are allowed. 3.11.3 Safety Harness Expiration The material of all straps must be Nylon or Dacron polyester and in new or perfect condition. All driver restraint systems must meet either SFI Specification 16.5/16.1, or FIA specification 8853/98 or ISI marks.The belts must bear the appropriate dated labels, and on Jan 1st of the competition year be no more than three years old.
3.12 Shoulder Harness

The shoulder harness must be the over-the-shoulder type. Only separate shoulder straps are permitted (i.e. Ytype shoulder straps are not allowed). 3.12.1 Vertical Location The shoulder belts must NOT be mounted above the shoulder level, and must be no more than 102 mm (4 in.) below the perpendicular from the spine to the seat back at the shoulder level. Shoulder belt must be entirely on cockpit side of fire wall and be protected by fire wall. It should run directly from mounting to drivers shoulder without twist & redirection by any part of vehicle. (Figure 20) 3.12.2 Lateral Spacing The shoulder harness mounting points must be between 178 mm (7 in.) and 229mm (9 in.) apart (Figure 19). The straps shall not pass through anything that will cause the center distance to be less than 178 mm (7 in.) from center to center of the strap. The straps shall not pass over anything that causes them to be more than 229 mm (9 in.) apart center to center. (Figure 19)
Fig. 19 - Distance of shoulder point
Fig. 20 - Vertical Location
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Fig. 21 - Lap belt specification
Fig. 22 Lap Belt Anchoring Method
3.12.3 Harness Attachment Points The shoulder belts must be looped around a horizontal tube welded within the RRH that meets the Roll Cage Secondary Member requirements of Rule 3.3.3.1. Lateral motion of the belts along their mounting tube must be restrained (Figure 23). The firewall must protect the entire shoulder belt. The firewall may be pocketed to facilitate this, as long as no open gaps result. In any case, the shoulder belts must be laterally constrained when passed through the seat.
Figure 23
3.13 Lap & Anti-Submarine Belts The lap belt must pass around the pelvic area below the Anterior Superior Iliac Spines (hip bones) (Fig. 21). 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 side view, the lap belt must be at an angle of between 45 degrees and 65 degrees to the horizontal. This means that the centerline of the lap belt at the seat bottom should be approximately 76 mm (3 in.) forward of the seat back to seat bottom junction (see Figure 21). To fit drivers of differing statures correctly, in side view, the lap / anti-submarine belts must be capable of pivoting freely by using either a shouldered bolt or an eye bolt attachment (Figure 22). Mounting lap belts by wrapping them around frame tubes is no longer acceptable unlike the case of Shoulder Harness. The lap belts should not be routed over the sides of the seat. 3.13.1 Specified Lap & Anti-Submarine Belts Mounting The frame tabs which accept the lap belt mounting tabs must meet the following requirements: 1) The lap belt tabs must be mounted in double-shear. (See Figure 22) 2) The frame tabs that accept the lap belt tabs shall be no less than 2.3 mm thick (0.90 in.) 3) The tabs mounted to the frame to accept the lap belt tabs shall have no less than 38 mm(1.5 in.) of weld length where mounted to the frame 4) These tabs shall have no less than 64 mm (2.5 in.) of material in the radial direction from the edge of the mounting bolt hole to the closest outside edge of the mounting tab. 5) Where the harness tab mounts to the frame tabs, the lap belt must be capable of pivoting freely about the axis of the mounting bolt such that the webbing and tab can align with the direction of the load. The height of the tab is free, but ultimately subject to the judgment of the Technical Inspectors. The mount should not exhibit noticeable deformation when pulled on during technical inspection.
NOTE: If the belts do not have enough adjustment capacity or improperly fitted, the vehicle will not be cleared for Technical Inspection. The final decision in this regard rests with the technical committee head.
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3.14 Arm Restraints

In the event of a rollover, the drivers arms must be kept within the limits of the cockpit. Arm restraints must be securely fastened to the driver restraint system, in a way that the drivers hands do not come out of the cockpit. Only commercially available arm restraints meeting SFI 3.3 are allowed. The arm restraints must independently connect to the safety belts. 3.14.1 Arm Restraint Expiration The belts must bear the appropriate dated labels, and on 1st Jan of the competition year be no more than three years old.
3.15 Braking System

3.15.1 Foot Brake
Figure 24
The vehicle must have at least two (2) independent hydraulic braking systems that act on all wheels and is operated by a single foot. The pedal must directly actuate the master cylinder (no cables are allowed). Each hydraulic system shall have its own fluid reserve either through separate reservoirs or by the use of a dammed, OEM-style reservoir. The brake system must be capable of locking ALL FOUR wheels in a static condition and dynamically on pavement AND an unpaved surface. Both the independent brake-systems may be actuated by a tandem master cylinder and safely stop the vehicle at max speed of 45kmph or above. All rigid brake pipes must be mounted securely along the roll cage / other members as required. Loosely hanging / pipes located by using ties / tapes etc shall not be permitted. Wheel ends should be connected with flexible pipe only. The bleed point location must lie on top of the caliper cylinders, without exception. Vehicles not meeting this requirement will not clear technical Inspection. This is in the interest of safety of vehicle & team. The brake(s) on the driven axle must operate through the final drive. Inboard braking through universal joints is permitted. Braking on a jackshaft or through an intermediate reduction stage is prohibited
NOTE: Plastic brake lines are not allowed. Use of OEM Brake lines is recommended.
3.15.2 Brake Light The vehicle must be equipped with a red brake light whose lens must be marked with an SAE S or U rating (i.e.: SAE IPRSTM) or if it is not rated as per SAE J759, it must be equal to or exceed these standards (e.g.: OEM brake light assemblies)/ AIS and ISI rated brake lights are also permitted. The determination of whether or not a brake light meets the required standards. The brake light must be mounted at a minimum of 1 meter (40 in.) above the ground. Light must be mounted such that it shines parallel to the ground, not at an angle, till a distance of 10 meters.
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3.16 Fuel System

3.16.1 System Location The entire fuel system must be located within the roll cage envelope such that it is protected from impact. The tank mountings are done along with B&S engine and need not to be changed. 3.16.2 Fuel Tank A single fuel tank (maximum capacity = 4.5 liter) is permitted on the vehicle which is supplied & mounted along with B&S Engine. Quality, cleanliness of fuel tanks is important from both safety & engine working point of view. 3.16.3 Spill Prevention: Drip Pan / Splash Shield A drip pan that is at least 203.2 mm (8 in.) in diameter or equivalent area and have sides of at least 38 mm (1.5 in.) high above the top edge of the tank is required so that if the fuel spills it must not come in contact with the driver or the engine or catch fire. Fuel must not get accumulate anywhere in the pan & it must drain through a drain line composed of pipe or tubing that carries the fuel to the bottom of the car and releases it under the car (to ground). At no point in the drain system (the drain lines and any associated fittings) will the inner diameter be constricted to less than 9.53 mm (0.375 in.) this includes bolts with a hole drilled in the center used as a fitting. A shake resistant Drip Pan below the fuel tank is must. Drip Pan is invariably also called as Splash Shield for its added functionality of preventing fuel being accidently spilled directly on engine or exhaust while re-fuelling or during the driving on tilt. 3.16.4 Spill Prevention Drain Material The drains must be either fuel line material, other pipe or tubing suitable for transferring fuel. Tubing that is weakened or dissolved by fuel are unsafe and will not be permitted. If tubing is used, it is highly recommended that a threaded and barbed fitting be used at the point where the drain line connects to the drip pan.
Figure 25: Approved illustrations for a spill/splash shield and working.
Figure 26: The above spill/splash shield is NOT acceptable
Fuel spill prevention shall be checked by a 45 degree tilt test at the technical inspection site or any point of time during the event with fuel tank filled completely with fuel. Any vehicle failing to comply this test shall not be allowed to start any dynamic event.
Figure 27- Tilt Test Layout (45)
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Compliance is mandatory. 3.16.5 Filler Cap A standard Briggs and Stratton gas cap with a built in check valve (Part # 792647) is required. The retail price must be included in the cost report The standard filler caps provided with rated fuel tanks may not prevent fuel from leaking in the event of a rollover. Teams must ensure that the filler cap gasket does not breakdown in fuel, does not have any holes and prevents fuel from spilling. The cap must not come loose during dynamic events or allow fuel to spill out even vehicle is tilted over banking. In case of such spill over observed all spill over fuel must get drain off through drip pan & drain pipe to ground. Compliance shall be checked and any vehicle failing to comply shall not be allowed to start any dynamic event. 3.16.6 Fuel The only fuel permitted is automotive gasoline consisting of hydrocarbon compounds. The gasoline may contain anti-oxidants, metal deactivators, corrosion inhibitors, or lead alkyl compounds such as tetra-ethyl lead. The addition of nitrogen bearing additives, or additives designed to liberate oxygen is strictly prohibited. Specific gravity should not exceed 0.75 for leaded gasoline or 0.80 for unleaded gasoline when measured at 60 degrees Fahrenheit, See Section 4.2.2 Competition Fuel Supply.
3.17 Steering & Suspension Systems

3.17.1 Wheel Stops All vehicles must be equipped with positive wheel lock-to-lock stops. These stops must mounted external to the steering gear and must be located on the non-rotating parts like knuckle/ uprights. Wheel stops must function at full jounce, full rebound and all points in between. No straps or cables are allowed. Compliance shall be checked and any vehicle failing to comply shall not be allowed to start any dynamic event. 3.17.2 Tie Rod Protection The tie rods of all vehicles must be protected from frontal impact. A bumper may be required, at the technical inspectors discretion, depending on the design and installation. Adjustable tie rod ends must be constrained with a jam nut to prevent loosening. 3.17.3 Handlebar steering Handlebar operated steering system is specifically prohibited.
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3.18 Fasteners
3.18.1 Fasteners All fasteners used in the systems designated in Section 3.18 must be captive; defined as requiring NYLON locknuts, cotter nuts or safety wired bolts (in blind applications). Lock washers or thread sealant do not meet this requirement.
Figure 28
3.18.1.1 Lock Wire Procedure Detail EXAMPLE: A team using a custom hub with an OEM rotor must meet the locking requirements, but a team using an OEM hub and OEM rotor would be exempt. The above figure illustrates the procedure for using lock wire: A. Above illustrations assume right hand threads. B. No more than three (3) bolts may be safe-tied together. C. Bolt heads may be safe-tied as shown only when the female thread receiver is captive, or the nuts meet previous lock nut requirements. D. Nuts (pre-drilled) may be safe-tied in similar fashion to the illustrations with the following conditions: 1. Nuts are heat-treated. 2. Nuts are factory drilled for use with lock wire. E. Lock wire MUST fill a minimum of 75% of the drilled hole provided for the use of lock wire. F. Lock wire must be aircraft quality stainless steel of .508 mm, .813mm, or 1.067mm diameter (0.020 inches, 0.032 inches, or 0.042 inches diameter). Diameter of lock wire is determined by the thread size of the fastener to be satisfied: 1. Thread sizes of and smaller use 0 020 wire 2. Thread sized of to use 0 032 wire 3. Thread sizes > use 0 042 wire 4. The larger wire may be used in smaller bolts in cases of convenience, but smaller wire must not be used in larger fastener sizes. 3.18.2 Fastener Grade Requirements All bolts used in the systems designated in Section 3.18 must meet SAE grade 5, metric grade M8.8 or AN military specifications. See Figures below. Acceptable SAE Bolt Grades:
Figure 29(a)
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Acceptable Military Specification Bolt Grades:
Figure 29(B)
3.18.3 Thread Exposure All threaded fasteners used in the systems designated in Section 3.18 must have at least two (2) threads. Compliance shall be checked 100% and failing to comply shall not be qualifying for technical clearance. 3.18.4 Socket Head Cap Screws Socket head cap screws, also known as internal wrenching bolts or Allen head bolts used, must meet one of the following requirements: 1) 2) The bolt head is clearly marked with the letters N S, 12.9, or 10.9 indicating a military /aircraft or highstrength metric fastener. No other markings will be accepted. Proper documentation is supplied, which must include a purchase receipt, and manufacturers documentation indicating the bolt strength
3.18.5 Single Shear Connections All tie rods in single shear must have a factory steel safety washer. Ball joints are the only exception. (Figure 32) 3.18.5.1 Tie Rods All tie rods in single shear must have a factory steel safety washer.
Figure 30
3.18.5.2 Ball Joints Any commercially manufactured ball joints or rod ends with studs are allowed. Student manufactured ball joints or rod ends with studs are specifically prohibited.
3.19 Guards
3.19.1 Power train Guards All rotating parts must be shielded to prevent injury to the driver or bystanders should the component fly apart due to centrifugal force. They must be mounted with sound engineering practice, in order to resist vibration. They must be either (a) made of AISI 1010 steel at least 1.524 mm (0.06 inch) thick or (b) a material having equivalent energy absorption at rupture per unit width of shield. Equivalency calculations for the alternative material must meet the following requirements: All calculations must be shown in SI units. Calculations must use the following material properties for the AISI 1010 steel: Yield Strength = 305 MPa, Ultimate Strength = 365 MPa, Elongation at Break = 20.0%, Modulus of Elasticity = 205 GPa. Documentation from the material manufacturer showing the Ultimate Strength, Elongation at Break, and Modulus of Elasticity of the alternative material must be provided. If a stress-strain curve for the alternative material is not provided then it
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must be assumed that the stress strain curve is linear to the yield point and linear from the yield point to the ultimate strength, where strain = elongation at break (Figure 31).
If a fiber reinforced composite material is used, then a stress strain curve must be provided for worst-case tensile loading. Additionally, the curve for the composite material must be specific to the matrix and manufacturing methods used. Compliance shall be checked and any reinforced composite material must be 3.175 mm (0.125 inch) thick. Vehicle failing to comply shall not be allowed to start any dynamic event. In order to show equivalency the calculation must show the following: (Area under curve for AISI 1010 Steel x Thickness) (Area under curve for alternative material x Thickness)
Figure 32
3.19.1.1 Side Shields Side shields must prevent fingers from getting caught in any rotating part. A complete cover around the engine and drive-train will be acceptable. 3.19.2 Clothing Drivers must wear appropriate clothing, including long pants (cotton/ Nomex), socks, shoes, gloves, and a long sleeved SFI/ ISI rated upper garment. The upper garment must have a factory label showing it is SFI rated, FIA rated or fire resistant. All restraints must bear appropriate dated labels, and on 1st Jan of competition year be no older than 3years.
3.20 Driver Equipment Requirements

3.20.1 Helmet, Neck Support/Collar & Goggles All drivers must wear a well-fitting Motor-Cross style helmet with an integrated (one piece composite shell) chin/face guard and a Snell M2005, SA 2005, ISI marks, British Standards Institution BS 6658-85 types A or A/FR. Goggles must incorporate the use of tear-offs or roll-off systems.
MOTOCROSS STYLE
Figure 33
No Street Bikes Style HELMETS

Figure 34
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Neck Support Permitted

Figure 35
NeckSupport-NotPermitted
Figure 36
In addition to the helmet, a neck support/collar must be worn. The neck support must be a full circle (360) and SFI 3.3 rated (Figure 35). Horseshoe collars are not allowed (Figure 36). Simpson, RCI, GForce, Deist or Leaf Racing Products supply neck collars that meet this requirement. Neck support must bear the appropriate dated labels, and on 1st Jan of the competition year be no more than three years old. WARNING: Some Motor-Cross helmets have extended chin guards that will not contact the required neck collars when the head is flexed forward. This combination of helmet/collar system is prohibited. Any non-specification helmets will be confiscated until after the competition. This rule has no exceptions and it will be strictly enforced. Helmets certified to other rating systems may not be worn. No compromise with Safety of driver.
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SECTION 4 - COMPETITION PROCEDURES AND REGULATIONS

4.1 Rules Clarification And Protests
4.1.1 Technical Questions Questions about the rules requirements and restrictions must be submitted by e-mail to the Technical Inspectors of the Baja SAE India at: bajatechfaq@gmail.com. Questions and answers will be posted on the Baja SAE India website at: www.bajasaeindia.org
NOTE: Please keep in mind that final operating approval of a BAJA SAEINDIA vehicle can only be given at the competition venue by the National Technical Inspectors.
4.1.2 Protests Any objection/matter must be brought to the notice of the organizers or SAE INDIA staffs attention for an informal preliminary review before a protest can be filed. Teams may not protest rule interpretations or actions that have not caused them any substantive damage. All protests must be filed in writing and presented to the organizer or SAE staff by the faculty advisor or team captain within one hour (60 minutes) of the end of the event to which the protest relates. In order to have a protest considered, a team must post a twenty-five (25) point protest bond which will be forfeited if their protest is rejected. The decision of the competition protest committee or National Technical Inspectors regarding any protest is final.
4.2 Competition Procedures And Regulation (general)

4.2.1 Drivers Meetings All team members identified as drivers and their support personnel MUST attend all drivers meetings. Failure to attend drivers meetings can result in disqualification of members or the entire team. 4.2.2 Competition Fuel Supply Fuel at the competition will either (1) be provided by the organizers or (2) the organizers will specify acceptable fuel providers. 4.2.2.1 Re-fuelling All refueling of the cars done in the pit area or on the course must be done with (1) the engine shut-off and (2) the driver out of the car. Any violations of this rule will be subjected to severe penalties. A fire extinguisher must be in hand whenever a vehicle is being refueled. 4.2.3 Engine and Drive-train Inspection The Technical Inspectors reserve the right to impound and inspect any vehicle during/ after the dynamic or endurance events. Any vehicle found to have: (1) a drive-train configuration not matching the Drive-train Certification Form submitted during technical inspection or (2) an engine in violation of rules Sections 2.2 through 2.2, 1.2, 2.3, 2.4 shall receive zero points (0) for all dynamic competition events completed during the day on which the inspection was performed. 4.2.4 Engine Recall Option The organizers and SAE India may, at their sole option, recall the engine from any vehicle in the competition in exchange for a new B&S engine. Recalled engines will not be returned and will be inspected at B&Ss facilities to confirm compliance with the rules. 4.2.5 Driving Restrictions When a vehicle is driven anywhere except the practice area or competition events, it must move at walking speed with a team member walking along side at a normal walking pace. The walking speed rule will be strictly enforced and point penalties will be assessed for violations, including impounding the vehicle for a specific period of time, at
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the discretion of the Technical Inspectors. Under no circumstances may anyone other than the driver ride on a vehicle. Drivers must wear all of the equipment specified such as seatbelts, helmets, goggles, wrist restraints, required clothing and a properly fastened restraint system at all times when the vehicle is running in any event or on the test track. Drivers not wearing the proper equipment will not be permitted to drive, and may have their competition drivers privileges revoked Practicing outside of the designated practice area will result in a minimum fifty (50) point penalty and/or the revocation of driving privileges depending on the extent of the infraction. DRIVING OFF-SITE IS ABSOLUTELY PROHIBITED. TEAMS FOUND TO HAVE DRIVEN THEIR VEHICLE AT AN OFF- SITE LOCATION MAY BE EXPELLED FROM THE COMPETITION. 4.2.6 Penalties Organizers have the right to modify the penalties listed in the various dynamic event descriptions to better reflect the design of their event courses, the course lengths or any special conditions unique to the site.
4.3 Rules of Conduct

4.3.1 Sportsmanship Good conduct and compliance with the rules are requirements for every team member. Owing to any unsportsmanlike conduct which can include arguments with officials, disobedience of official instructions and the use of abusive or threatening language to any official or other participant, the organizer is authorized to impose an appropriate penalty. 4.3.2 Alcohol and Illegal Material Alcoholic beverages, firearms, weapons of any type and illegal materials are prohibited at the Baja SAE India site during the competition. The penalty for violation of this rule is the immediate expulsion of the entire team, not just the individual(s) involved. This rule applies to team members, advisors and any individuals working with the team on-site. Disruptive parties either on or off-site should be prevented by the faculty advisor. 4.3.3 Site Condition Please help the organizers keep the site clean. Failure to clean the premises will result in an unsportsmanlike conduct penalty. Competitors and spectators are encouraged to police their areas after meals.
4.4 Safety Team Responsibility

Safety is the primary consideration in the design of BAJA SAEINDIA vehicles and the conduct of the competitions. Teams need to include safety considerations in all parts of their program. At all performance events, it is the responsibility of the team to ensure both the vehicle and driver meet and follow all the requirements and restrictions of the rules. The teams are required to maintain the code of conduct throughout the event, failing which they may have to face point penalties or even disqualification.
4.5 Spectator Rules

The competitors, faculty and volunteers are expected to help inform the spectators of the safety rules and help restrict spectators to the spectator areas. Spectators may not drink alcoholic beverages at any event location. Spectators must keep well back from the event and practice tracks and from any area where vehicles are operating under power. Spectators who fail to strictly control their children will be asked to leave the site. The course officials and organizers have the absolute right to restrict spectator access to any parts of the site and to eject anyone who violates safety rules or ignores the instructions of officials.
Note: All teams, spectators and faculty members are responsible for the safety of their own, their vehicles and belongings. No claims regarding these shall be entertained by the organizers.
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Section 5 - Technical Inspection

5.1 Self-Certification
Participating teams are required to carry-out a self-certification check at their end by the due date of 30th Dec. 2012 and complete the check sheet. The list of documents/ certificates/ video clips etc. and the check sheet completed in all respect with the actual measurement values are to be submitted to the technical inspectors.
5.2 Technical Inspection at College level

1. 2. The college level technical inspection is scheduled between 15th Jan 2013 to 31st Jan 2013. The inspection will be carried out by the trained technical inspectors at respective colleges. The teams are required to demonstrate weld check, workshop facilities, brake-test, figure of 8-test, tilt test, vehicle validation procedures/ facilities etc. during the technical inspection. 3. The completed Self-Certification Check Sheet duly signed by the faculty advisor and team captain should be sent to BAJA Technical Committee. Teams should download the most current version of the Self-Certification Check Sheet and thoroughly inspect their vehicle in accordance with the sheet. Only on the confirmation from the technical inspectors, the teams will be allowed to participate in BAJA SAEINDIA 2013. Teams are liable to be DISQUALIFIED from participation in BAJA SAEINDIA 2013 on NONCOMPLIANCE with the rulebook. The decision of technical inspector will be final and non-challengeable.
4.
5.3 On-site Safety Scrutiny

The objectives of On-Site safety scrutiny are to (1) Ensure engine is in proper operating condition & does not over speed 3800 rpm. (2) Ensure compliance with the safety parameters for the vehicle & driver. (3) Compliance of basic requirements mentioned in the rulebook. (4) Validate the vehicle performance by conducting preliminary tests. On the very first day at the BAJA site, the team need to report with Self -Certification Check Sheet duly signed by technical inspector at college level. Once it is confirmed that the vehicle is ready for Safety Scrutiny it has to go through the following sequence1) Fuel Filling 2) Stage 1- Engine Inspection (Engine OK Sticker Issue) 3) Stage 2- Safety Scrutiny & Figure of 8 (Safety OK Sticker Issue) a. 64-Inch (GO-NO-GO) Gauge b. 45 Degree Tilt Test c. Overall Safety Scrutiny d. Fig of 8 - Test for turning & maneuverability (30 - 40 kmph) 4) Stage 3- Panic Brake test at 45 kmph (Brake OK Sticker Issue) 5.3.1 Zero Tolerance Policy All BAJA SAEINDIA vehicles must pass Safety Scrutiny in two attempts only. During the safety scrutiny, vehicle has to be in running condition, full tank fuel topped-up condition and should be capable of undergoing for all the test sequence mentioned above. The inspectors at site will give two attempts to all for each test and team need to comply for the same within the stipulated time. Hence, it is mandatory to get certified with the same Technical Inspector who has examined the vehicle at the first attempt (every test of the sequence bears dedicated inspectors). No special request for 3rd test will be entertained. The time will be logged for the complete Technical Inspection for each vehicle to evaluate the best. The parameters - college level perfection & the shortest possible time in clearing the technical inspection.
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To satisfy the requirements and restrictions of the BAJA SAEINDIA rules, teams need to take the best efforts at college level manufacturing and ensure the vehicles are complete in all aspects. The Self-Certification is vital for the commitment towards ensuring the basic quality standards aimed at completing the Technical Inspection on the 1st day of the event. If vehicles are not ready on the day of technical inspection, teams are liable to be rewarded with point-deduction. Teams not carrying Self Certification Check Sheet verified and approved by technical inspectors, will be debarred from further participation. Faculty advisors are not allowed to participate during technical inspection. The team captains or other designated members (maximum 5) of the team must be present during Inspection. Vehicles that do not pass the technical inspection will be disqualified for all other events and cant participate in Dynamic and Endurance Tests. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all.
5.4 Inspection Stickers

Technical inspection comprises of three stages. A three-parts inspection sticker (see Section 5.3 Engine OK/ Safety OK/ Brake OK Stickers) will be issued in sections to the team as each of the three stages of technical inspection is completed. The inspection sticker must remain on the vehicle throughout the competition. Technical inspectors and officials may remove any or all parts of the inspection sticker from any vehicle that has been damaged or which they reasonably believe may not comply with the rules. Stage 1 -Engine Inspection OK Briggs and Stratton staff is responsible for the Engine Inspection of each vehicle. To expedite the process, each team needs to arrive with side cover removed and loosened bolts of fuel tank mounting with spare air filter kit. Engine inspection will consist of - the engine rpm setting with governor position verification, after-installation of new air-filter element and working of kill switch. The inspection ensures(1) Setting of the governor at 3800 rpm & spring at 6th notch position, and (2) Engine compliance for normal performance. On successful completion of Stage 1, the First sticker will be put on the firewall. Stage 1 must be passed before a team may apply for Stage 2 inspection. Stage 2 - Safety Scrutiny & Figure of 8 Each vehicle will be inspected to determine its compliance with the rules and restrictions. This inspection will include an examination of the drivers equipment including helmet and arm restraints and a test of driver exit time. ALL THE REGISTERED DRIVERS ARE MANDATORILY REQUIRED DURING SAFETY SCRUTINY. Each team must bring the following items to inspection; if they do not have the items at the time of inspection they will receive a 10 point deduction for each item missing or not completely filled: a) Self-Certification Check sheet: With self checks carried out by team and verified by Technical Inspector (Format is due to be posted on www.bajasaeindia.org by 10th November 2012. Team is needed to download and ensure the compliance). b) Tube Specification Certificate: Obtained from supplier with latest testing certificate from local laboratory (Section 3.7). c) Roll Cage Specification Sheet: Completed Roll Cage Specification Sheet. (See Section 7 - Appendix 1) d) Safety equipment and drivers kit The following tests will be carried out in the sequential manner during this stage(a) 64 inch GO-NO-GO gauge (b) 45 deg tilt test for fuel spillage and drain (c) Wheel lock stoppers (d) Accelerator pedal returnability (e) Free operation of gear shift and hand brake (f) Reverse lamp functionality
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(g) Specified hardware and nylon lock nuts (h) Safety belt and restraints as per specification (i) Egress test of all drivers (j) Figure of 8 test and maneuverability On successful completion of Stage 2, the Second sticker will be put on the firewall. Stage 2 must be passed before a team may approach for Stage 3 inspection. Stage 3 Dynamic (Panic) Brake Testing Both the external and cockpit kill switches will be tested for functionality. If both switches pass the test then the vehicle will be dynamically brake tested. Each vehicle must demonstrate its ability to lock all four wheels and come to rest in an approximately straight line after acceleration run to reach at least 45 kmph or as specified by the inspectors. If a vehicle fails to pass any part of the inspection it must be corrected/ modified and brought into compliance with the rules before it is permitted to operate. The inspectors and officials have the right to re-inspect any vehicle at any time during the competition and require correction of any non-compliance.On successful completion of Stage 3, the Third sticker will be put on the firewall. Acquiring the three stickers marks the completion of Technical Inspection and makes them eligible for Dynamic Evaluation.
NOTE: 1. All drivers must be present at technical inspection, in case of failure the names of driver will be removed from the Final list of drivers and a 10 point penalty will be applied to the team. 2. Teams presenting Self Certification Sheets that are (1) incomplete, (2) inaccurate (i.e. do not correspond to the actual condition of the car) (3) are found to have more than 3 items not in accordance with the rules, or (4) do not represent a serious effort at pre-inspection will be denied inspection at that time and sent back to the end of the inspection line with a 100 point deduction /other penalties which shall be prominently displayed at the site at least 60minutes before commencement of Technical Inspection of the first vehicle. 3. Overall Vehicle Inspection Flow-
INDEX (Figure 37): 1. Engine Check 2. 64-Inch (GO-NO-GO) Gauge 3. 45 Degree Tilt Test 4. Overall Safety Scrutiny 5. Figure of 8 Test 6. Panic Brake Test
5.5 As-Approved Condition

Once a vehicle has passed technical inspection its configuration may not be modified. Approved vehicles must remain in as-approved condition throughout the competition Necessary repairs that do not significantly change the configuration of the vehicle are permitted. Minor adjustments permitted by the rules and normal vehicle maintenance and tuning are not considered modifications. NOTE: It is important for every team to get their vehicle approved by the technical scrutiny during which the safety, integrity of vehicle structure, fabrication processes adopted, etc will be judged. The team shall provide documented proof of fabrication process of every component and the design analysis, failing which they may have to face point penalties or disqualification. THE BAJA SAEINDIA TECHNICAL COMMITTEE RESERVES THE RIGHT TO DISALLOW ANY VEHICLE FAILING TO COMPLY WITH THE REQUIREMENT OF THESE RULES TO TAKE PART IN ANY DYNAMIC EVENT TILL THE VEHICLE IN QUESTION IS RECTIFIED, REPRESENTED AND PASSES THE TECHNICAL INSPECTION. FOR THIS COMPLIANCE, MAXIMUM NUMBER OF RE-INSPECTIONS PER VEHICLE (BESIDES THE NORMAL INSPECTION AT SITE) SHALL BE 2 (TWO) ONLY. THIS REQUIREMENT SHALL BE ENSURED WITHOUT EXCEPTION. THEREFORE, IT IS REQUIRED THAT TEAMS COME WITH THEIR VEHICLES WELL PREPARED FOR THE EVENT, TO AVOID DISAPPOINTMENT. The decision of the Head of the Technical Committee of BAJA SAEINDIA in this regard will be final and binding to all. This is in the interest of safety.
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SECTION 6 - BAJA SAEINDIA EVENTS

6.1 Static Events
The static events comprise of Design Evaluation, Cost Evaluation and Marketing Presentation. Teams are required to clear the Static Event at different panels assigned for specific evaluation. Important instructions for Static Event1. 2. 3. 4. 5. 6. BAJA SAEINDIA 2013 participating vehicle MUST be available for Design and Cost Evaluation. Design Report and Cost Report are mandatory during Design and Cost Evaluations respectively. During Marketing Evaluation business case needs to be explicitly presented dealing with manufacturing and marketing strategies/plans. There are 3-4 rows (with panel of judges) for each Static Event namely Design Evaluation, Cost Evaluation and Marketing Presentation. Teams are required to choose any one of the available rows and clear the same before proceeding to next static event. In case of failure at the first attempt in Design Evaluation, teams are allowed for ONLY 1 more attempt (2nd attempt) at the same judges panel.
STUDENTS CAN INDEPENDENTLY APPROACH TO STATIC EVALUATION EVEN IF FAILED IN TECHNICAL INSPECTION.
6.2 Dynamic Events

The dynamic events are intended to determine how the BAJA SAEINDIA vehicles perform under a variety of conditions. Please note that the organizers have the right to modify the dynamic events to address local conditions, weather or resources. 6.2.1 Speed Events 6.2.1.1 Acceleration A. Objective Acceleration determines the time it takes the vehicle to accelerate along 100 ft (30.48 m) or 150 ft (45.72 m) flat course. The choice of course length is at the organizers discretion. B. Acceleration Procedure Each team may make two (2) attempts. Scoring will be based on the better of the two attempts. Timing may be done using either electronic systems or stop watches. C. Acceleration Penalties The organizer has the right to modify the penalties imposed for different violations to account for differences in the length or design of specific event courses. False Start or Stall at Start : First False Start Second False Start Leaving Course : D. Acceleration - Scoring If the time taken for acceleration by a team is more than twice that of the fastest car, it will not receive a score for this event. Teams attempting the event, but exceeding the time limit will be classified as Excess Time. The following equation will be used for the acceleration score: Disqualification Rerun at end Disqualification
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Acceleration score = 100 x [(TLongestTyours)/ (TLongestTShortest)] Where: T Shortest is the fastest time by any team. T Longest is either a. The slowest time by any team or b. 2 times the fastest time, whichever is the shorter interval. T yours is the best time of your team. 6.2.2 Traction Event The traction events are designed to demonstrate the vehicles ability to use its traction to accomplish various tasks. At the organizers discretion, the traction event will be either the hill climb or a pulling event. 6.2.2.1 Hill Climb A. Objective Hill climb assesses each vehicles ability to ascend a steep grade from a standing start. B. Hill Climb Procedure
Each vehicle may make two (2) climbing attempts with the best distance or the fastest completion time counting for score. Once the vehicle stops moving forward the attempt is over and the attempt is scored for distance at that point. Vehicles may not continue the attempt after they have stopped on the course. If a vehicle stalls before reaching the top of the hill, or if its wheels are spinning without moving the vehicle forward, the attempt is scored for distance at that point. C. Hill Climb Event Penalties
The organizer has the right to modify the penalties imposed for different violations to account for differences in the length or design of specific event courses. Leaving Course: False Start: D. Hill Climb Scoring Method A: Everyone Climbs the Hill If all of the teams succeed in completing a full climb, then the score will be based on the time of the climb and calculated by the following formula: Hill Climb Score = 100 x [(TLongestTyours) / (TLongestTShortest)] Where: T Longest is the longest time by any team. T Shortest is the shortest time by any team. T yours is the best time of your team. Method B: No One Climbs the Hill If none of the vehicles succeeds in climbing the hill, then the score will be based on the distance each team climbs as determined by the following formula: Hill Climb Score = 100 x [(Dyours DShortest)/ (DLongestDShortest)] Where: D Shortest is the shortest distance climbed by any team. D Longest is the longest distance climbed by any team. D yours is the best climb of your team.
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Score equals distance covered before course violation. First False Start Rerun at end Second False Start Disqualification
Method C: Some Teams Make the Climb If at least one team makes the climb while other teams do not, then the vehicles making the climb (Group I) will be scored based on time and the vehicles that stop on the hill (Group II) will be scored based on distance traveled. Scoring will be by the following formulas: Group I: Teams that complete the climb Score = 100 x (TFastest / Tyours) Where: T yours is your teams best time T Fastest is the fastest time by any team Group II: Teams that stop on the hill Score = (Lowest score from Group I) x (Dyours / Dhill) Where: Dyours is the distance traveled by your vehicle. DHill is the length of the hill from the starting point to the finish line.
6.2.2.2 Maneuverability Event A. Objective Maneuverability is designed to assess each vehicles suspension, handling and steering. The course may consist of a variety of suspension and handling challenges, at the organizers option, possibly including tight turns, pylon maneuvers, ruts and bumps, drop-offs, sand, rocks, gullies logs, and inclines. B. Maneuverability Procedure
Each vehicle may make two (2) runs with the best time, including penalties, counting for score. C. Maneuverability Penalty Default Values
The organizer has the right to modify the penalties imposed for different violations to account for differences in the length or design of specific event courses. Obstacle/Pylon moved Missed gate* : : 2 seconds 10 seconds Run disqualification First False Start Second False Start *Missed gate is when 2 or more wheels are outside the gate D. Maneuverability Time Limit Only vehicles that complete the maneuverability course within a time not exceeding two and half times (2.5X) that of the fastest vehicle will receive a score. If a vehicle is on the course for a time that exceeds twice the fastest time Rerun at end Disqualification
Deliberate course violation : False Start :
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recorded to that point then the Event Captain may declare the attempt over, remove the car from the course and score the attempt as Excess Time. E. Maneuverability Scoring Maneuverability scoring is based on the vehicles time through the course including any penalties. Maneuverability Score = 100 x [(TLongestTyours)/ (TLongestTShortest)] Where: T Longest is either (a) the longest time through the course by any team or (b)2.5 x T Shortest whichever is the shorter time T Shortest is the shortest time through the course by any team T yours is your teams time through the course
6.3 Practice Round

One hour time will be dedicated to practice on endurance track those who have successfully completed Technical Inspection and Dynamic Event.
6.4 Endurance Event

6.4.1 Endurance Objective The endurance event assesses each vehicles ability to operate continuously and at speed over rough terrain containing obstacles in any weather conditions. 6.4.2 Endurance - General Description Endurance run may be based upon either total time taken or total distance covered. Endurance events for time usually run for four (4) hours. Endurance events for distance continue until at least one car has gone the specified distance. Endurance will be run as one of the following(A) A single four (4) hour race, (B) A predetermined and published distance, or (C) Elimination heats followed by a final in which the total time of one elimination heat plus the final is 4 hours. The organizer will announce the structure of the event prior to the start. Determining the winner of the endurance race: The team, which completes the distance of the competition first, or the greatest distance in the time set for the competition will be declared the winner. In competitions of a given distance, the checkered flag will be given first to the leading car, then to the other finishers as they cross the finish line. In competitions of a timed length, the checkered flag will be given first to the leading car as it crosses the finish line at or after the expiration of the specified duration, then to the other finishers as they cross the finish line. If the leading car is not running at the expiration of the time limit, the checkered flag will be given to the next highest running car in the same manner.
6.4.3 Endurance - Starting The starting grid for endurance will be based on each teams performance in a previous dynamic competition, or set of dynamic events, to be determined by the organizer. All vehicles will be considered to have begun the race simultaneously at the time when the starter releases the first vehicle onto the course regardless of their actual position in the grid.
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6.4.4 Endurance Command Flags Command flags are just those flags which must be immediately followed by participants without any dissent. Green Flag (1) At a starting line or when re-entering the course: Your run, or session, has started; enter the course under the direction of the starter. (NOTE: If you stall the vehicle then restart and wait for another green flag as the opening in traffic may have closed.) (2) While running on the course: Course is clear, proceed. Yellow Flag, Steady Danger, SLOW DOWN, be prepared to take evasive action, something has happened beyond the flag station. NO PASSING, unless directed by the course workers. Yellow Flag, Waved Great danger, SLOW DOWN, evasive action is likely to be required, BE PREPARED TO STOP, something has happened beyond the flag station. NO PASSING, unless directed by the course workers. Red Flag Come to an immediate safe and controlled stop on the course. Pull to the side of the course as much as possible to keep the course open. Follow course worker directions. NO PASSING. Black Flag, Furled and Pointed Warning, the officials are watching your driving obey the event rules. Black Flag, Displayed (1) Pull into the penalty box for a discussion with the Director of Operations or other official concerning an incident. A time penalty may be assessed for the incident. (2) Pull into the penalty box for a mechanical inspection of your car, something has been observed that needs closer inspection. Checkered Flag Your run, or session, has been completed, exit the course at the first opportunity. 6.4.5 Endurance Stalled or Disabled Vehicles Disabled or stalled vehicles must be immediately removed from the roadway. It is the drivers responsibility to assist and cooperate with the course marshals in removing the vehicle. Cars may only be started with the driver seated with all belts properly fastened. The driver may not exit the vehicle to execute a restart. Course marshals, volunteers or team members may assist drivers in restarting their vehicles. Officials and course marshals may stop any vehicle, at any time, if they believe it no longer complies with the requirements and restrictions of the rules. If a vehicle is stopped by officials for a mechanical fault, the fault must be corrected / repaired before it may reenter the event. 6.4.6 Endurance Repairs The organizer will announce the rules governing repairs that are permitted to be made during the endurance event. If repairs along the course are permitted then vehicles under repair must be removed well off the course, away from the outside of turns and away from any natural run-off areas. 6.4.7 Endurance Event Penalty Default Values The organizer has the right to modify the penalties imposed for different violations to account for differences in the length or design of the course Failure to stop for Black Passing under a Yellow Flag Deliberate Ramming Flag 10 minutes or 1 lap per flag* 1 lap penalty First time = Second time = Deliberate Forcing another Vehicle off the course First time = Second time = Third time = Leaving Course and Advancing 5 minutes 10 minutes Disqualification 10 minutes 20 minutes Disqualification
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Driving in an Unauthorized Area Failure to Yield to Traffic on Entering Track Speeding in Pit Area Fueling
10 minutes 5 minutes 5 minutes 30 minutes
Fueling will not be allowed until the engine is turned off, the driver is out of the car, and a fire extinguisher is ready. No work will be done on the car when fueling. * whichever the official determines is the greater penalty. 6.4.8 Endurance Scoring A. General: The endurance event score is determined by (a) the number of laps each team completes during the endurance final and (b) the finish order of teams at the end of the event. Scored laps are the number of full laps actually completed during the endurance event final. Only full the laps count, partial laps do not count for score. A vehicle must cross the counting/timing line under its own power for a lap to be counted. Finish order is the sequence in which vehicles cross the finish line after the lap scoring period has ended. Finish order determines the ranking of teams completing the same number of laps. For example, if the top four teams finish with the same number of laps, then they will be ranked 1st to 4th based on their finish order. Bonus points are additional points awarded to the first ten (10) vehicles on the leading (winning) lap, as separated by finish order as required, in part to differentiate teams finishing with the same number of scored laps. Up to 10 bonus points will be awarded in the inverse order of finish. Thus, the first vehicle to cross the finish line in the highest lap group will receive bonus points equal to the number of cars on the lead lap (max of 10); the second vehicle will receive one less bonus point etc. Endurance scoring is based on number of laps the vehicle completes in the allowed time: Endurance Score = [400 x (LYoursLLowest)/ (LHighestLLowest)] + bonus points Where: L Highest is the highest number of laps completed by any team. L Lowest is the lowest number of laps completed by any team. L Yours is the number of laps completed by your team. B. Endurance Heats plus a Final Point Distribution:
When endurance is run as heats plus a final, the points for the event will be distributed between the heats and the final in proportion to the time/distance of each stage. Thus, if endurance is run as one (1) hour eliminations plus a three (3) hour final, the four hundred (400) total points will be allocated as one hundred (100) points to each elimination heat plus three hundred (300) points to the final. 6.4.9 Tie-breakers There will be no tiebreakers for static events. Tiebreakers for dynamic events will be the second best run time or score for the given tied event. If both scores for tied teams in the event are equal then the tie remains. Ties in the endurance race will be judged by the endurance event judge and may remain a tie. Ties for overall winner will be broken by the following criteria: Endurance score Total dynamic events score Total static events score If a tie remains after all the above tiebreakers then the tie remains for the overall winner(s).
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SECTION 7 - APPENDIX
BAJA SAE ROLL CAGE SPECIFICATION SHEET APPENDIX 1 2013 BAJA SAE INDIA COMPETITIONS
COLLEGE NAME _________________ CAR NUMBER_______________________
This sheet MUST be completed and submitted in accordance with the event rules.Failure to do so will result in penalty. Purpose: The purpose of this sheet is to facilitate verification of roll cage materials/construction,and to provide a means of tracking the age of older vehicles. This is being done in theinterest of safety and good engineering practice.
1. 2. 3.
Academic year the cage was constructed? ___________________________________ Material Type (ie: 4130): _____________ OD: _______________ Thickness: _______________
Primary Welder: ______________________________ Type of Filler Material: ___________________________
Welding Method Used:_______________ Shielding Gas Used: _______________
4. 5.
Equivalency calculations if needed (attach to this sheet). All welds and/or other attachment methods must be checked for integrity. Faculty advisor andteam captain are requested to do destructive testing on sample joints that represent the integrity of similar welds on their frame (per Rule 31.2.11). ____________ (DATE)
Sign of Technical inspector with date: _________________ (SIGNATURE) NOTE:
It is extremely important that such an inspection be made, and for those constructed of materials (i.e. aluminum) which do not exhibit and endurance limit.
WE HAVE EXAMINED THE ABOVE INFORMATION AND TO THE BEST OF OUR KNOWLEDGE DEEM IT TO BE ACCURATE. TEAM CAPTAIN __________________________________________ (SIGNATURE) FACULTY ADVISIOR __________________________________________ (SIGNATURE) Faculty Advisor e-mail: _________________________________ (SIGNATURE) ___________________ (DATE) ___________________ (DATE) ___________________ (DATE)
Team Captain E-mail : ____________________________________________________________ Faculty Advisor E-mail : ____________________________________________________________ BRING A COMPLETED COPY OF THIS FORM WITH YOU TO TECHNICAL INSPECTION. ALSO BRING THE MATERIAL SPECIFICATION CERTIFICATE AS PROVIDED ALONG WITH THE ROLL CAGE MATERIAL BY THE VENDOR.
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APPENDIX 2 Local Technical Inspection Rules / Violation Penalties for 2013

Names & contact details of Technical inspectors and their allotted colleges will be put on the official BAJA 2013 website by mid of Dec. Allotted teams will directly contact the Technical inspectors for mutually fixing Technical inspection dates for the local level Technical inspection. At least an early intimation of 30 days should be made by the teams so as the tech inspector can make necessary arrangement for visiting college campus for local inspection. At Local level inspection, vehicle should meet at least a minimum of 80 percent Rule book and inspection sheet criteria; it also includes a Figure of 8 test and a panic brake test at the local level inspection. Any team, if found to have fabricated their vehicle using professional assistance or from a Standard kit would be liable for a penalty of 400 points or may be ineligible to compete. Failing above 80 % criteria at local level , the teams will be penalized a 50 point penalty & if the team is found below 60 % conformance criteria , the vehicle will not be allowed at the main event . Last date of technical inspection at college level will be 30 Jan 2013 and all the teams will adhere to the deadlines for inspection. The teams failing to above timelines automatically gets eliminated out of the BAJA 2012 event. Teams must retain the Original Technical Sheet /all the Documents of proof along with them only Teams will then submit these documents at the Main technical Inspection site at Indore only, failing which teams may be disqualified from the main event also. Only one Re-inspection will be conducted during the main event, failing which the teams will be disqualified for the dynamic events. BAJA main Technical inspection will start one days prior to the Starting day of the Main event at the Pithampur site and no Technical inspection will be conducted on a later date (i.e. .Dates for Inspection at the main site for pre qualified vehicles will be ____Feb2013) Teams shall be penalized with a minimum deduction of 50 points subject to the any Design modifications done after the conclusion of Static event. Teams unable to submit welding samples of adequate quality shall not be eligible to complete in any dynamic or endurance event. Any vehicle exhibiting handling or other vehicle dynamics that are deemed unstable by the technical inspectors will not be permitted to participate in the dynamic events. Any deviation from the kill switch specification would attract penalty of up to 200 points. (With Indian standards marks) The Baja SAEINDIA Technical Committee reserve the right to impound any on-site registered vehicle at any time during a competition for failure to comply to the discipline of the event at all times. This impound time shall be 180 minutes per incident. Extensive use of readymade subassemblies may invoke penalties. Team representatives must be present during the comparison to discuss the design changes. If the judges find that the design changes are (A) not significant, (B) not supported by a detailed analysis or (C) have not been sufficiently documented, then a penalty of up to three hundred (300) points may be assessed against the design score Any vehicles found unsafe at any given time of the event will not be allowed to run .The decision of the Head of the Technical Committee of Baja SAEINDIA in this regard will be final and binding to all. This is in the interest of safety.
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APPENDIX 3 RECOMMENDATIONS OF CODE OF CONDUCT DURING BAJA SAEINDIA 2013

If a technical inspector at site finds the vehicle incomplete during his/her final technical level vehicle inspection, the team is likely to attract penalty / rejection as deemed fit by the organizers. Any team performing any welding operation at site should do it in a defined area preferably with empty fuel tanks. Teams which do not pass inspection at the 1 inspection may be penalized as deemed fit by the organizers. No one else will be permitted other than team members to work on vehicle if found so, the complete team may be penalized as deemed fit by the organizers, which may include disqualification. 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 vehicles with supporting evidence. The decision of the organizers in this regard will be final and binding on all parties.
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Virtual BAJA SAEINDIA

APPENDIX 4 A. Objective
The Virtual BAJA SAEINDIA is a pre-qualifier to participation in the BAJA SAEINDIA event. The objectives of the Virtual BAJA Event are as follows: 1. 2. 3. 4. 4.1 4.2 4.3 To acquaint the teams completely with the objectives of the BAJA SAEINDIA event. The teams are required to acquaint themselves with the technical guidelines and limits for the design of BAJA vehicle. To design the complete CAD Model of the BAJA Vehicle. The design should be complete in all respects to the extent of being considered ready-for-manufacture. The teams would be judged on the following basis: Knowledge of rulebook Project Plan Design
4.3.1 Extent of completion of vehicle design 4.3.2 Design Methodology 4.3.3 Roll Cage Design 4.3.3.1.1 Materials Used 4.3.3.1.2 Compliance with rulebook 4.3.3.1.3 Finite Element Analysis A. Pre-Processing (framing the parameters, constraints, loads etc.) B. Post-Processing (result analysis, changes in design, etc.) C. Human Ergonomics 4.3.4 Suspension, Steering & Brakes 1. Chosen configuration (disc, drum brakes, type of suspension, steering geometry, etc.) 2. Specifications (stopping distance, suspension travel, tie-rod length, turning radius, caster,camber, toe-in, toe-out, braking effort, pedal force etc.) 3. Suspension Design (wishbone, A-arm, trailing arm design, wheel hub, knuckle design, shock absorber, damper mounting, travel, etc.) 4. Brake Design (braking effort, braking circuit, brake mounting, etc.) 5. Steering Design (geometry, turning radius, power assistance etc.) 4.3.5 Power train 1. Engine (engine specifications, mounting, emission control, intake, exhaust design, fuel system, fuel lines, transmission coupling etc.) 2. Transmission (chosen configuration, engine coupling, max speed, traction, power, acceleration, final drive to wheels, wheel size, joints, etc.) 3. Wheel Size (wheel mounting, joint with final drive, etc)
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4.3.6 Body & Electricals 1. Weight (target) 2. Electrical System (safety, battery placement, kill switch, routing etc.) 3. Ergonomics 4. Aesthetics 4.3.7 Safety 4.3.8 DFMEA 4.3.9 Innovation 4.3.10 Design Validation Plan 4.3.11 Vehicle Completion Date & Technical Inspection Date B. Selection 1. Based on the performance in the Virtual BAJA, the teams would be selected for participation in the main event. 2. The selection would be purely on the basis of merit. 3. ONLY ONE TEAM PER COLLEGE shall be allowed on the basis of comparative merit. C. Scoring Knowledge of rulebook Project Plan Roll Cage Design Over all Vehicle Technical Specification & Target Suspension, Steering Brakes Power train Safety Design Validation Plan Total 50 50 50 50 25 25 25 25 50 50 400
The qualified teams would be required to submit the design report soon after the Virtual BAJA event. The design presented during the event shall be considered as final and the team shall be considered to proceed towards fabrication activity using the same design. Failing this, the teams shall be penalized / disqualified if the fabricated vehicle does not exhibit correlation with the design report or if the teams fail to fabricate within the stipulated timeframe. NOTE: The Virtual BAJA is a pre-qualifier, thus, no ranks or awards would be issued for the Virtual BAJA even
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APPENDIX 5 Design Report Format

(A) Format Design reports must follow the format for SAE Technical Papers. (Please use bullets wherever possible & max 10 pages + 4 pages for illustration) (B) Electronic version The design report must be submitted electronically in Adobe Acrobat Format (PDF) The document must be a single file (text, drawings and optional content are all inclusive). The design report file must be named as follows: Team reg. ID, Institute abbreviated name (C) File Size The maximum size for the file is 5 megabytes. Introduction The author should describe the introduction of the project, the expected performance, design methodology & outcome. Generally Applicable: Methodology of design as to why the particular configuration has been selected over other options, the design iterations done to get the desired configuration, etc. Technical Specification- Vehicle Performance Target and 3D Views (10 Marks) Engine Drive Suspension Wheels Brake Steering Dimensions Weights The expected target vehicle performance (speed, acceleration, stopping distance, deceleration, gradeability, turning circle diameter, ground clearance, emissions, fuel consumption). 3D View of the Complete Vehicle The CAD view and the isometric view of actual vehicle Roll Cage Design & Driver Ergonomics (15 marks) Design Considerations Material Used Static & Dynamic FEA Results Weight Material Properties Selection Criteria Driver Ergonomics Ergonomic considerations for driver comfortDesign for driver ergonomics. Front & Rear Suspension Design (10 Marks) Design considerations, target specifications, calculations, innovation, picture, design selection, criterions, design data, sprung and un-sprung mass, spring design considerations, travels and safety factor. Roll/ pitch suspension layout- camber / caster / toe in, bump steer calculations, any other features etc. Steering Design (5 marks) Design selection criterions, lay-out, steering geometry, turning angles/ diameter, steering effort etc. Brake System Design (5 marks) Design considerations, weight transfer, brake system details and calculations, lay-out, pedal force versus deceleration. Powertrain Design (10 marks) Power unit mountings, NVH considerations if any, over all transmission ratios and maximum speed/ gradeability in each gear, inlet air filter/ exhaust system, fuel tank, drive line lay out, output shaft angularities for the full suspension travel, total weight of drive line parts. Body Panels and Safety Equipment (10 marks) Weight considerations and the design of body panels. The safety features used in the vehicle. Engineering Bill of Materials (5 marks) Innovations (Separate Evaluation) Any innovation if used in the vehicle References & Acknowledgment / General Presentation (5 marks)
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APPENDIX 6 BAJA SAEINDIA Cost Report Format

ILLUSTRATION: BOM of a Cost Report Block PTE PTT Part Name Part No. Level Qty 1 1 1 2 Cost Manufacturing No. of Cost of Total (Procurement) Operations Operations Operations Cost 28,000 15,00 10 5 1 Guideline for Cost Report for Baja SAEINDIA 2013 The cost report is based on Bill of Materials. Its based on indentifying unique components required to build the vehicle assembly / sub-assemblies. The parts may be classified as Parent (Level1) or Child (Level 2) depending on whether its being assembled to vehicle directly. If it is in the form of another unit or sub-assembly which is assembled on vehicle subsequently. Example: Gears in gearbox are Level 2 parts while gearbox is Level 1 part. The BAJA SAEINDIA COST Sheet comprise of three sheets: Sheet 1: It indicates the overall cost of the vehicle, manufacturing cost, procurement cost, total no. of parts used, etc. It gives a brief overview about the cost and Bill of Materials for the BAJA Vehicle. Sheet 2: It is the Bill of Materials Sheet. Herein, the students are required to fill in the following details: i.Block: If the vehicle is considered as an assembly of the following major aggregates: Engine, Suspension, Transmission, Roll Cage, Electricals & Instrumentation (E&I), each one is regarded as a building block of the BAJA Vehicle. The teams are required to classify all the parts used in building the vehicle into either of the blocks as mentioned in the Index Sheet. ii. Part Name: Every unique part is to be identified with a unique name. The part should be named in a manner that it reflects the level of usage in the vehicle (e.g.: Gearbox Assembly indicates the gearbox is an assembly part). iii. Part Number: Every unique part is to be identified with a unique part number. The part number should be a 10 digit number with the first three digits indicating the block, the next five digits classify the part number and the next two digits represent the level of hierarchy. The codes for block are mentioned in the sheet, the teams are required to judicially choose the part number and revision number. iv. Level: Indicates whether the part is the parent part (Level 1) or whether it is a child part (used as an entity in a parent assembly) (Level 2). The teams are required to fill either 1 or 2. v. Quantity: The number of such parts to be used. For ex.: if the team plans to use the same wheel at all four locations in the vehicle, the cost is to be determined for a single wheel with Quantity as 4. vi. Procurement Cost: The teams are required to mention the procurement cost of the finished product/ raw material required to build the vehicle. The teams are required to fill the MRP (without taxes), irrespective of whether the part is a fresh sale or resale based procurement or even if it is sponsored. The MRP must be mentioned for all the parts and must be supported through Original bills / invoice/ quotes etc. vii. Manufacturing Operation: The teams must mention the manufacturing operation for each part, to be required to bring it to the final shape for assembly in the vehicle. The codes for each operation are mentioned in the index sheet. The teams are required to fill the exact code as mentioned in the index sheet. For multiple operations it is required to fill the manufacturing details in subsequent rows (only manufacturing operation is to be filled with the number of operations). Please note that the manufacturing cost includes the raw material required for the operation, for example: filler material for weld. The teams DO NOT have to add the cost of filler material. It is already taken into account in the standardized cost. The standard tables also define the specification of the operation. For example: the cost of welding is based on a 10 mm weld length. The students need to identify the no. of such welds L SW GW GR NA 10 1 2 150 12 10 0 28,000 1,800 120 50 0
Engine PTEENGIN00 Chain PTTCHAIN00
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required for the completion of the job. For example: to weld the roll cage, the outer diameter of the roll cage pipes is to be considered, divided by 10 (mm) would give the no. of operations required for completion. This would be the cost of a single joint. The total joints and total no. of operations are to be considered for determining the cost of the roll cage. In such a case, roll cage is also to be considered as an assembly of various pipes (RRH, SIM etc. which constitute the child parts of the roll cage). Thus the cost of child parts may be established for a better and clear estimation. In case the cost of the parent is determined completely by its child parts, the costing fields of the parent may be left blank as the cost would be indicated by the child parts. Wherever there is no manufacturing operation applicable, please mention NA. viii. Cost of Operation: The cost of operation is standardized as in the index sheet. The teams are ONLY required to fill the codes as specified in the index in the Manufacturing Operation column. Cost would be indicated automatically. ix. Total Cost: It is the sum of procurement cost and manufacturing cost. Sheet 3: It is the index sheet. This sheet is to be referred for cost, operations, etc. Please note that the BAJA SAEINDIA Cost Event is meant for the teams to determine the vehicle cost precisely and accurately and NOT to the minimum. It is not necessary that the vehicle with the LOWEST COST would be awarded the maximum score. Instead in such case, there would be an adjustment cost added to the cost as indicated by the team. This would be multiplied by an adjustment factor (penalty point) and the final adjusted cost may come out to be higher than the incurred cost. It is thus suggested for the teams, to accurately determine the cost of the vehicle and not minimize the cost intentionally. The objective is to find out the cost of the vehicle if a fictitious firm manufactures the BAJA vehicle at a rate of 4000 vehicles per annum. IT IS ENTIRELY THE RESPONSIBILITY OF THE TEAM TO UNDERSTAND THE GUIDELINES AND FORMULATE THE COST OF THE VEHICLE AS PER THEIR UNDERSTANDING. THE COST ADJUSTMENT WOULD BE DONE AT THE JUDGES DISCRETION. ANY DISCREPANCY IN DATA / FOULING WITH THE FORMULAE WOULD LEAD TO DISQUALIFICATION / PENALTY IN THE COST EVENT.
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APPENDIX 7 Index Sheet for Process Cost Reference

Operation Lathe (1000 mm3 volume) CNC (1000 mm3 volume) TIG (10 mm length) SMAW Welding (10 mm length) Gas Welding/Gas Cutting (10 mm length) Drill (1000 mm3 volume) Reaming (10 mm depth, 10 mm diameter) Boring (10 mm depth) Grinding (100 mm2 area) Super finishing (100 mm2 area) Filing (100 mm2 area) Riveting (per rivet) Shaper (1000 mm3 volume) Milling (1000 mm3 volume) Shearing (10 mm cut) Cutting (10 mm cut) Gear Hobbing (10 mm width per teeth) Rack Cutting (10 mm width per teeth) Pneumatic Operations (Requiring Pneumatic Source) Special Manufacturing Operation (actual expense incurred) Other Block Codes Powertrain - Engine, Intake & Exhaust Powertrain Transmission Roll Cage & Body Suspension, Steering & Brakes Electricals & Safety Standard Parts (Fasteners, Joints, etc.) Code L C TW SW GW D R B GR SF F RV SH M SG CT GH RC PO SP O PTE PTT RCB SSB EEE STD Cost 10 5 8 15 12 5 10 10 5 15 5 5 10 15 5 5 20 20 15
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APPENDIX 8 STATIC EVENT PARTICIPATION SHEET

TEAM No.: _______________ REGISTRATION ID: _______________ The participating team must get the sheet signed by Judge Panel for various Static Events & submit the same at the end of the clearing Static Event to event coordinator. Failing to this the team would not be considered eligible for scoring in static events. EVENT Originality & Innovation Feasibility for Mass Production Driver Comfort & Ergonomics Serviceability Suspension Steering & Brake Power train Structural Design Craftsmanship Emission Low idle rpm Emission High idle rpm Cost Event Marketing Presentation Sign of Judge (Head of Panel)
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APPENDIX 9 BAJA SAEINDIA 2013 Scoring Static Events Category Location No.
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1 11 12 1 2 1 2 1 2 3 4 5
Sub-group
Technical Specs / 3 D view of vehicle Roll cage design Suspension design Steering & Brakes design` Powertrain Design Body panel / Safety equipment Engineering Bill of materials General Presentation References etc. Innovation (vis--vis earlier Innovations) Craftsmanship Suspension Front Suspension Rear Steering Brakes Power Train Roll cage Body 0Feasibility for mass production Serviceability Operator Comfort / Ergonomics Cost Report Bill of Materials Cost Criterion Discussions with team / Cost reductions Prototype costs (by formula) Presentation flow Timelines Effectiveness and solidity of aids Clarity of Technologies and ideas USP coverage and Customer Satisfaction Answers: Confidence / concise / correct
Marks
Design Report
Off Site
75
Design Evaluation
On Site
125
Cost Report & Costs
Offsite Onsite
20 30
Technical Presentation
Onsite
50
Dynamic Events Dynamic Events Endurance Events Endurance Events On Site 1 2 3 Acceleration (Speed Event) Hill Climb Maneuverabilty 100 100 100
Onsite
Endurance Event (max duration = 4 hrs.)
400
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APPENDIX 10 BAJA SAEINDIA 2013 Awards

Details of Various Awards Given in Event will be hosted on BAJA SAEINDIA official website. Safe Vehicle Award Criteria: ZERO TOLERANCE is the theme for BAJA SAEINDIA 2013. This is, chiefly, considered on the basis of the total compliance of BAJA SAEINDIA vehicle with the official RULEBOOK during the college-level and the main event-level Technical Inspection and on clearing of the OnSite (main event) Safety Scrutiny (Section 5.3) in First Attempt & Shortest Time. The number of attempts for the On-Site Safety Scrutiny is important and the time taken, to clear it, will be recorded for each team. Hence, it is very important for a team to ensure 100% compliance for Self Certification as well as the high quality of build so that there is no re-work during the main event. The number of attempts for the On-Site Safety Scrutiny is important and the time taken, to clear it, will be recorded for each team. Hence, it is very important for a team to ensure 100% compliance for Self Certification as well as the high quality of build so that there is no re-work during the main event.
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APPENDIX 11 BAJA SAEINDIA 2013 Penalty Structure

Particular Cost / Design Report Registration Document Fee Engine Order Technical Inspection Technical Inspection (on-site) Brake Test Fuel Code of Conduct Vehicle Repairs in Pit Event Timings Traffic Guidelines Vehicle Movement Others Professional Help in Vehicle Build On line Submission of Self certification Compliance for Tech. Insp. at Local level ON SITE Technical Safety Scrutiny Design Modification after Static Events Kill Switch Vehicle Impound Design Change Accident / Violent Driving / Driving off the track Judgment Criteria Submission as per timeline All required details provided Full payment of fee before the deadline Full payment of fee and submission of documents as per the deadline Compliance as indicated in rulebook OR as (off-site) per guidelines of technical committee Compliance as indicated in rulebook OR as per guidelines of technical committee in maximum of 2 evaluations by the committee Compliance as per the test Running the vehicle without Tech OK & Brake OK Unruly behavior / misconduct with organizing committee / volunteers / other participants / spectators Accident prone activity Presence after closure of pits Accident on account of driving the vehicle at the site (non-dynamic events) Vehicle to be pushed with engine off Subject to case Any professional assistance sought during vehicle design or build or validation Due date submission for Self certification submission on line Compliance. 100% compliance Local level Technical Inspection Sheet with pre declared reports must be present during the on-site Tech Any modification done to the design Deviation from specification As per judgment of Technical Committee Deviation from design report Driving in pit areas / violent driving instruction / accident prone drive & damage to other teams or Volunteer on test ground Penalty No evaluation of reports Disqualification Disqualification 100 points / Disqualification 400 points Disqualification from Dynamic Events Disqualification from the event 200 points / Disqualification 200 points / Disqualification 300 points 200 points 1000 points 50 points per case Subject to case 400 points or Disqualification 25 points Disqualification Disqualification from Technical Inspection Minimum 50 points 200 points 180 minutes per incident Up to 300 points 1000 points / Disqualification for next three years
*The penalties described above are for overall conduct of the event and not particular to any of the specific static / dynamic events. The event specific penalties are specified in the rulebook. The penalties may change subject to case.
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APPENDIX 12 BAJA SAEINDIA 2013 CONTACTS Name & Company

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) Nirmal Matharu, Mahindra 2 wheelers Lalitkumar Suryawanshi, Cummins Sagar Bendre, NATRIP Dr. K. C. Vora, ARAI Sanjay Nibandhe Harshit Merchant Dr. P. P. Chattaraj, NATRIP Dr. N. Karuppaiah, NATRIP Akhand Pratap Singh, SAE INDIA B. Dinesh, SAE INDIA Vinay Mundada, Consultant Rajeev Mokashi, Consultant Juggal Mittal Cummins Ms. Taru Singhal, GE Ms. Parul Chaddha, GE Mrs. Prof. Thrumalini, SAE Engg. Board S. Puviarasu, B&S
Position
Convener Joint Convener Co-Convener Advisor Technical Committee Head Dynamic & Endurance Event Head Advisor Advisor Coordinator Coordinator Static Event Head Scoring Virtual Convener & Student Matters Virtual Convener & Student Matters Student & OC Coordination Engine Co-ordination
Direct Communication to any member of organizing committee shall not be entertained and shall not be considered as official. Following mail id are provided for respective communications 1. Technical Issues & Questions 2. General Communication 3. General Issues/ Query 4. Engine Related Query 5. Alumni/ Student Contact 6. Administrative Issues 7. Online submission / Web site bajatechfaq@gmail.com bajasaeindia2013@gmail.com saeindia_indore@saeindia.org puviarasu@ppepl.com Sanjay Nibandhe Sagar Bendre/Akhand Pratap Singh Akhand Pratap Singh S. Puviarasu Taru Singhal Sagar Bendre Akhand Pratap Singh
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Revision # 01 5th November, 2012

Zero Tolerance Policy

Section 1 - General Information

1.2 Top 10 Teams - Design Comparison Requirement

Section 2 - Vehicle Requirements and Restrictions

2.2 Required Engine

2.3 Engine Requirement and Restrictions

2.4 Engine Use Restriction

2.5 Battery Requirements

2.6 Component Failure

2.7 Engine Use Restriction

2.9 Reverse Light and Alarm

2.10 Towing Hitch Point

EXAMPLES OF ACCEPTABLE FRONT HITCH POINT

EXAMPLES OF NOT ACCEPTABLE HITCH POINT

Cut a ways are not allowed

2.11 Vehicle Identification

Section 3 - Roll Cage, Systems and Drivers Equipment Requirements

3.3 Roll Cage

3.4 Head Restraint

3.5 Driver Head Clearance

3.6 Roll Cage & Bracing Materials

3.7 Roll Cage Specification Sheet:

3.8 Roll Cage Padding

3.9 Bolted Roll Cages

Fig. 17 - Mounting illustration in vehicle

Fig. 18 - Schematic for Kill Switch Mounting

3.11 Driver Restraint

3.12 Shoulder Harness

Fig. 19 - Distance of shoulder point

Fig. 20 - Vertical Location

Fig. 21 - Lap belt specification

Fig. 22 Lap Belt Anchoring Method

3.14 Arm Restraints

3.15 Braking System

3.16 Fuel System

Figure 25: Approved illustrations for a spill/splash shield and working.

Figure 26: The above spill/splash shield is NOT acceptable

Figure 27- Tilt Test Layout (45)

3.17 Steering & Suspension Systems

Acceptable Military Specification Bolt Grades:

3.20 Driver Equipment Requirements

No Street Bikes Style HELMETS

Neck Support Permitted

SECTION 4 - COMPETITION PROCEDURES AND REGULATIONS

4.2 Competition Procedures And Regulation (general)

4.3 Rules of Conduct

4.4 Safety Team Responsibility

4.5 Spectator Rules

Section 5 - Technical Inspection

5.2 Technical Inspection at College level

5.3 On-site Safety Scrutiny

5.4 Inspection Stickers

5.5 As-Approved Condition

SECTION 6 - BAJA SAEINDIA EVENTS

6.2 Dynamic Events

Deliberate course violation : False Start :

6.3 Practice Round

6.4 Endurance Event

10 minutes 5 minutes 5 minutes 30 minutes

Primary Welder: ______________________________ Type of Filler Material: ___________________________

Welding Method Used:_______________ Shielding Gas Used: _______________

Primary Welder: ____ Type of Filler Material: _

Welding Method Used:_ Shielding Gas Used: _