Team STRATOS

HOW TO BUILD A GOOD BAJA ATV

(BUGGY) IN 40 STEPS
1. SUCCESS AT BAJA= DEDICATED TEAM +
SMART CAPTAIN + HELPFUL FACULTY ADVISOR
2. DIVIDE THE TEAM, RESEARCH, BRAINSTORM,
DISCUSS, DEBATE AND ARGUE
3. MAKE A BASE PLAN AND THEN 3D CAD
WIREFRAME
4. BUILD PROTOTYPE OF SPACE FRAME. ESP.
FOR FIRST TIMERS
5. CAD MODELS AND ANALYSIS
5A. PRELIMINARY AND FINAL MODELS
6. OBTAIN A NICE AND TIDY WORKSHOP
7. SET TABLE ACCURATELY AND MAKE
MARKINGS
8. START FROM THE BASE WITH NECESSARY
MATERIALS
9. FINALIZE AND SECURE BASE
10. BUILD UPWARDS USING EFFECTIVE JIGS,
MAINTAINING ACCURACY ALL THE WHILE.
 ALL CHANGES(IF ANY) MADE IN THE PHYSICAL MODEL MUST
BE REFLECTED IN THE CAD MODEL
11. ACCURATE EDGE PROFILES ARE CRUCIAL
12. SPOT TALENTED WELDER(S), ENCOURAGE
SUFFICIENT TRAINING AND START WELDING
12A. GOOD WELDS ARE THE SECRET OF A GOOD
CAR
13. SCHEDULE WELL THROUGHOUT
14. KEEP SPONSORS IN THE LOOP
15. ENSURE FIT OF CRITICAL COMPONENTS
16. COMPLETE FRAME
16A. NOW BRING THE FRAME TO THE DESIRED
RIDE HEIGHT. HELPS IN SUSPENSION BUILD
17. WORK ON SUB-COMPONENTS MUST BE
ATLEAST HALF WAY THROUGH
18. ALSO ARRANGE FOR ALL ACCESSORIES
19. START THE ASSEMBLY!
20. FINISH CRITICAL COMPONENTS FIRST:
A-FRONT SUSPENSION
B-REAR SUSPENSION
C-HUBS
D-STEERING ASSEMBLY
E- DRIVETRAIN
F- BRAKE LINES, TIE RODS AND INNOVATIONS
(IF ANY)
21. INSTALL THE OTHER ESSENTIALS: SEAT,
SAFETY KIT, ETC
22. ELECTRICAL AND BODY PANELS ARE
OPTIONAL AT THIS STAGE
23. TIME FOR THAT FIRST EVER TEST DRIVE!!
24. DISCUSS IMPROVEMENTS NECESSARY
25. STRIP DOWN ALL THE PARTS FOR PAINT
JOB. START BY SPRAYING RED OXIDE
26. MAKE IMPROVEMENTS TO OTHER PARTS OF
THE CAR SEPARATELY.
27. APPLY PRIMER ON THE FRAME
28. MIX PAINT WITH THINNER APPROPRIATELY
AND TRY OUT
29. NOW GIVE ATLEAST 2 COATS OF PAINT
30. RE-ASSEMBLE THE CAR
31. COMPLETE THE CAR TO THE MAXIMUM
EXTENT: BODY PANELS, INNOVATIONS, ETC
 - COCKPIT
Speedometer
DIGITAL FUEL
GAUGE - Hidden
multimeter with
custom fit LEDs!

Lights

DIGITAL GEAR
INDICATOR

Dual tone 4 terminal (IG-

N123 I-Pattern
dashboard Horn button BI-15-ST)
Gear shift
Ignition switch
32. RUN FIELD TESTS FOR ATLEAST A MONTH
(CRITICAL)
33. MAKE YOUR COLLEGE COME TO LIFE AT 3AM
34. HOPE THINGS FAIL HERE SO YOU CAN YOU
CAN BE SAFER ON RACE DAY
35. TEST MORE AT TOUGHER PLACES.

Courtesy: Dirt Mania ATV dirt track, Kanakpura Road, Bengaluru

36. HOPE MORE THINGS FAIL AT THE RIGHT
TIME
37. REPAIR AND TEST EVEN MORE.
38. GO BACK TO GARAGE. CLEAN UP, TOUCH UP
39. SHIP TO RACE TRACK
40. KEEP TOOLS AND SPARES HANDY AND
HOPE FOR THE BEST AT BAJA!!
IF THINGS DON’T WORK OUT, DON’T BE TOO
DISHEARTENED..
..YOU MIGHT STILL GET TO WIN ANOTHER DAY!
MY PROFILE..
 I had the wonderful opportunity to be the captain of the much acclaimed 'Car#8-
BOSCH Team Stratos, BIT', the team representing the institution at the BAJA
SAEINDIA 2010 Competition, held at NATRAX, near Indore, M.P. This was the first
time such an attempt was made in our college and were the only ones from
Bangalore.

 Apart from being the skipper, I had a major role in the design phase of the all-terrain
vehicle (ATV), using CATIA V5 extensively in part design, assembly, anthropometric
analysis and use of in-built analysis package. I was involved in marketing as well,
with the team getting major sponsorship backing from Bosch Ltd., among many
other prominent companies. I’ve created the Team sponsorship brochures. Also have
designed and implemented all the electrical systems in the car.

 My team consisted of 20 brilliant 4th, 3rd and 2nd year mechanical students. Our car
was used to inaugurate the event as our team had won laurels for having the Best
Design Report.

 We got our first podium finish at the BIAE ATV University Challenge when we finished
at 2nd place in a 21Km endurance race.
A FEW TIPS..
 You are most likely to have one shot at BAJA. So, keep reliability of all
aspects largely within spec.

 Test, test and test more. Parts break when you least expect. This is
that sort of terrain. I suggest atleast a month’s testing.

 Never EVER underestimate your opponents.

 Rule: OEM parts are ALWAYS more reliable than custom made ones.

 Respect the track. Its professionally crafted to reduce your car to

shreds. This is where your worst case scenario is your most likely
scenario.
MY BEST WISHES TO ALL FUTURE BAJA
ASPIRANTS!!

-Manish O.
THANK YOU!

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