Team Ojaswat (car no.

52)
Cost explanation document

Engine
The team has upgraded from KTM 390 to GSX-R 600 deriving 97.5 bhp from inline 4
cylinders common rail fuel injector engine. Although it was an expensive option compared
to the previous season, we have shifted to this engine for the following reasons

• For better acceleration and bhp

• References of previous design

We procured the bike for 3689.02 € to meet our engine requirements.

The intake manifold is made of FRP coated on a wooden pattern instead of 3D printing or
aluminium. Hence it is cost effective yet leak proof at the same time. The FRP cost us 84.5€
And wood pattern cost us 55.9€.
The exhaust runners and muffler is made of SS instead of titanium for ease of manufacturing
and cost effective at the same time. The material for manifold cost us 22.65€ and process
cost us 4.5€. The material for muffler cost us 33.48€ and process cost us 2.93€
The radiator is custom made ACR instead of OEM used in previous car for better cooling of
4-cylinder engine. Radiator with shroud in total cost us 195€.

Drivetrain
The department consists of the following components.
• Hubs
• Uprights
• Differential
• Axle
• Differential mounting
Hubs are machined from AISI 4340 blooms costing 2.6€/kg. Machining process includes
CNC turning, vertical milling and chromium plating. The total cost of machining per hub
totalled to 102.57€.
Uprights are machined from Aluminium 7075-T6 billets costing 9.49€/kg. Machining
process includes vertical milling and anodizing. The total cost of machining per upright
totalled to 260€.
Differential being used in the car is an open dry type instead of limited slip differential as it
is a much cheaper alternative and meet our requirements. The differential cost us 149.76€.
Axle used in the vehicle were custom made meeting our requirements. They are standard
axle with tripod and constant ball CV joints on either side. The axle pair in total cost us
194.35€.
Differential mountings are machined from Aluminium 6061-T6 billets costing 3.9€/kg.
Mountings are milled on VMC for price of 6.5€ per hour.

Exchange rate - (1Inr = 0.013€)

Brake

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 Team Ojaswat (car no. 52)
Cost explanation document

We tried using custom made split master cylinder of 19mm bore for balancing but were not
able to achieve the desired balancing so we shifted to KBX tandem master cylinder which
cost us 24.85€ . We are using Royal Enfield Flexi line which cost us 10.81€ and rigid line
which we used is from Maruti Suzuki whose cost is6.24€ instead of SS braises Flexi line
because of the cost efficiency.

Brake, accelerator and clutch pedal are machined on VMC and material used is aluminium
6061 whose price is 3.9€/kg and the machining cost is 6.5€/hour. The reason behind using
VMC machining process are
maintain 5:1 pedal ratio
bearing tolerance for balance bar beRING
Ergonomically AND AESTHETICALLY SOOTHING.

We used DOT 3 brake fluid whose cost is 1.3€ /250 ml which is very easily available as
compared to DOT 4 brake fluid.

We have upgraded to wildwood GP200 from Bajaj Pulsar 220f because of the following
reason:- better packaging
more brake pad area
multiple bleeding points
Wildwood callipers are Double piston fixed calliper whose cost is 129.844€.

We used laser cut machining processes for pedal box where the machining cost and material
cost was 15.34€.

Suspension system
Dampers cost us 273€ in total. Springs are custom manufactured from oil tempered steel.
AISI 4130 tubing material was used instead of aluminium and carbon fibre for suspension
links, tubing and bell cracks. The cost for material was 2.17€/Meter and cost for
manufacturing was 16.25€. The manufacturing process which was used was laser cutting the
reason behind using this process is to obtain high accuracy of angel.
The cost for manufacturing of each rocker arm was 53.69€. The manufacturing process used
was laser cutting and the material used was plain carbon steel.
We used anti roll bar and the cost for the bearing used is 3.12€ the bearing used was GE12E.
The cost for housing was 20.15€.

Wheel, wheel bearing and tires

We are using Keizer forged aluminium wheels which are light in weight as well as has good
strength.It is made from aluminium 6061-T6.
Each wheels cost us 208.33€.
We are using Hoosier 44115 which are wet type tires which helps in providing enough grip
for our car. Each tire cost us 281.71€.

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 Team Ojaswat (car no. 52)
Cost explanation document

In case of bearing, we are using a set of 2 single row tapered bearing on each hub
which has the ability to withstand both axial as well as radial forces acting on it. It also has
the
capacity of carrying heavy load which ensures that it will not fail during hard braking. Each
bearing cost us 17.25€.
We have bought an extra set of tyre from Carlisle 205/50-10 the cost for each tyre is 68.25€.
Steering
Steering wheel: steering wheel is manufactured from teak wood whose cost is 3.12€. Steering
wheel is made by VMC machining for accurate cutting and wood finishing. The
manufacturing cost was 6€/hr.

Shafts: Steering shaft is manufactured from SS 304 for better torsional rigidity and strength.
˜The cost for material for each shaft is 3.9€. The manufacturing process used was lathe
machining the cost was 7.8€. The diameter of the shaft was decided from the calculation of
torsional rigidity.

Bevel gears: Bevel gears are manufactured from mild steel and after that they were harden
for increasing its wear strength . Gears were made from robbing process and it is the more
accurate process for manufacturing of gear the manufacturing cost for each bevel is 15.32€.

Bevel housing: The material used is Aluminium 6069 T6 and the material cost is 5.3€. The
process used for manufacturing is milling process and the machining cost is 13.65€.

Rack housing: Rack housing is the part which holds rack and pinion assembly. It is made up
of aluminium 6063 T6 whose total cost is 23.4€. The manufacturing cost is 46.95€.

Bearing cover: The material used is Aluminium 6069 T6 and the material cost is 2.08€.
The manufacturing process use is lathe machining and the total cost is 4.42€.

Rack support: The material used is Aluminium 6069 T6 and the material cost is 12.48€.
The manufacturing process used is milling process and the total manufacturing cost is 26€.

Rack and pinion: the manufacturing material used in rack is SS 304 and the cost of material
is 7.8€.
The manufacturing process used is milling process and the manufacturing cost is 15.6€.
The manufacturing material used for pinion is SS 304 and the material cost is 3.64€. The
manufacturing process used is milling process and the manufacturing cost is 7.41€.
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Clevis: The material used for manufacturing of clevis is Aluminium 6063 T6 whose total
cost is 7.28€. The manufacturing processes used is lathe machine and milling and the total
cost is 14.82€.

Tie rod: Tie rod is made of steel. The cost of material and manufacturing is 2.86€.

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 Team Ojaswat (car no. 52)
Cost explanation document

Bearing: The bearing used are 6301-ZZ and the cost is 1.05€.
The other bearing used are 6302-ZZ and 6804-ZZ and the cost is 1.15€ and 0.65 respectively.

Electrical
Item Cost in euro

Wires € 20.2

Throttle positioning sensor € 19.89

Manifold air pressure sensor € 25.16

Roll over sensor € 16.12

Fuel pump € 73.89

Injection valve € 41.57

Gear positioning sensor € 39.72

Crankshaft positioning sensor € 46.18

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 Team Ojaswat (car no. 52)
Cost explanation document

Alternator € 75

Engine control unit € 230.94

Relay € 43.41

Fuse box € 14.78

Brake system plausibility device € 190

Battery charger € 45.5

Pressure sensor € 105.57

Battery € 26

Master kill switch € 32.98

Inertia switch € 111.18

Rectifier € 18.47

brake over travel switch € 1.3

Kill switch € 31.2

Brake switch € 0.61

Electronic components € 14.67

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 Team Ojaswat (car no. 52)
Cost explanation document

FRAME AND BODY

So we started with manufacturing of fixtures by laser cutting manufacturing process which

cost us in total €153.4. The material used is mild steel and the material cost is €76.7.

The chassis is made up of AISI 4130 pipes. We have used variable thickness tubes to
achieve maximum stiffness to weight ratio. Total cost of the material is

We have done further process on pipes of both roll hoops. We have done bending process
for both the pipes. We have done tube notching as per the profiles for those pipes where
required. We have got plates of different sizes for different mountings. Welding process
was done to join all pipes and
mountings. Total cost of processing on frame was 19222 rupees.