Session: ASME Undergraduate Student Design Expo

Paper Number: 175682

Mcneese State University Baja Sae Car Design 

This study presents the design, development, and evaluation of McNeese State University’s first-ever race car. The primary goal is to create a fully functional, durable, off-road vehicle capable of excelling in static and dynamic events, with particular emphasis on structural robustness, subsystem integration, and serviceability.

 

The design process began with benchmarking of prior Baja SAE vehicles and comparable commercial off-road platforms, followed by computer-aided design (CAD) modeling and Finite Element Analysis (FEA) to assess structural and functional feasibility. Key performance targets included a curb weight of 400 lbs, a top speed near 35 mph, and adequate suspension travel and ground clearance for rugged terrain. While the final vehicle achieved a curb weight of 480 lbs and a measured top speed of 29 mph, these values remained within functional tolerances.

 

The chassis was constructed using 1020 Drawn-Over-Mandrel (DOM) steel tubing selected for strength-to-cost optimization. Comprehensive crash simulations, including frontal, side, rollover, rear, torsional, and bump scenarios, were conducted, applying forces up to 33 kN to simulate worst-case impact conditions. Results demonstrated effective energy absorption in designated crumple zones and minimal deformation of the driver cell, validating both structural integrity and occupant safety. Ergonomic design was informed by anthropometric data of the team’s drivers, optimizing seat, pedal, and steering placement for comfort during endurance events.

 

The drivetrain consists of a Comet 780 primary clutch, a Polaris secondary clutch, a Sportsman 500 transmission, and a Polaris RZR front differential. Custom driveshafts and extended constant-velocity axles were fabricated to integrate these subsystems. Analytical calculations predicted a maximum speed of 34 mph, with testing confirming a slightly lower actual value. The team emphasized modular and serviceable design, which enabled rapid part replacement using readily available commercial components.

 

Suspension and steering were designed for manufacturability and integration with Polaris knuckles. FEA simulations, including a 5-foot drop test under a 308 kg load, indicated acceptable stress levels and deformation profiles across front and rear suspension arms. Kinematic analyses showed minimal camber variation, enhancing handling predictability. The braking system, built around Polaris hardware and custom pedal tabs, was validated against the SAE requirement of 2000 N pedal force, with FEA confirming negligible deformation under load.

 

Overall, the final vehicle successfully met core design objectives of functionality, durability, and compliance. While slightly overweight and marginally underperforming relative to top speed targets, the prototype demonstrated robust subsystem integration, validated structural safety, and ease of serviceability. Future iterations will prioritize weight reduction, structural refinement, and performance optimization while retaining the modular and cost-effective design philosophy.

Presenting Author: Feng Dung McNeese State University

Presenting Author Biography: Mechanical Engineering Major from McNeese State University. Member Society of Automotive Engineers.

Authors:

Feng Dung McNeese State University
Samson Odutola McNeese State University
Zachary Brewester McNeese State University
Audrey Borel McNeese State University
Logan Loftin McNeese State University
Braxton Smith McNeese State University