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2024 Fall Update
2024 is ending which means it’s the perfect time to do all the design work we couldn’t get done during the semester when we were “going to class.” While we didn’t have any races this fall, lots of work was poured into the 2025 missile slowly taking shape in Hudson. I’ll take this time to hit just some of the highlights from each subsystem this semester.
Aerodynamics
The aero philosophy this year is centered on doing the simple things well. With a new effort to improve aero efficiency over downforce alone, both front and rear wings have shed an element this year with 2 elements per wing. Rest assured, DRS will be back for 2025. Additionally, we’ve returned to bonded wing assemblies over bolted connections to increase rigidity and reduce part count and weight. The rear wing will also sport just two lower mounting arms instead of four to decrease compliance while the front wing loses the faspins in favor of bolts for the same reason. Floor and sidepod designs are under development and turning Ansys FLUENT sims fast. The aero team closes out the fall semester with a fully manufactured front wing in our signature mylar gloss, a rear wing ready for assembly, and lots more layups on the horizon.
Chassis
Chassis goes into winter break with their most complex part completed – the chassis. This year’s chassis is a bit wider but has lost a few tubes in the rear box and the rear front hoop brace in the name of weight and ergonomics. Most importantly, the team secured our first podium of the season in the sheets instead of the streets with the 2nd fastest SES approval time. Once again, our friends up north at VR3 helped us out with CNC notched tubes that made frame manufacturing a breeze. Ritz and I comfortably dominated the welded chassis betting line by over a week. This quick turn around could not have been accomplished without the anti-warping forearms of our human jig and team President, David Gorman. The remaining cockpit component development is taking place over the break. Most notably, another custom composite steering wheel with an integrated PCB is near final. We have made the switch to aluminum shifter paddles over the 3D printed parts that gave us trouble last season.
Electrics
The first half of the semester for electrics was spent troubleshooting a variety of electrical gremlins on E95 and on the dyno. We were hoping to start the semester with a regional race at Michelin Proving Grounds in South Carolina. However, a banana’d connecting rod and a handful of related mechanical and electrical issues kept us from glazing our favorite 14-acre asphalt pool table. Nonetheless, the electrics folks designed and manufactured the bulk of a new dyno harness, with a main body harness imminent as well. Steering wheel and BSPD PCBs are also scheduled to be released for manufacturing in the next week. The ECU, PDM, BSPD and relays have been relocated to the right side of the car, away from the radiator to improve accessibility. Electronic throttle control is making a return this year to keep our ETC Review Form judge employed as well as to give us some tasty launch control and rev matching.
Operations
It was a stellar semester for the Operations crew. In addition to our regularly scheduled appearances at the club fairs, Durham School Days and Wine & Design, the team made it to the Duke Women’s Basketball program’s Education Day to show off some engineering to local elementary and middle school students. We also hosted a SpaceX recruiting event at the garage and were lucky enough to tour the GM Motorsports facility in Concord, NC. On the sponsorship side, we secured funding from the Alumni Engagement and Development organization to support our Electrics alumni design review. Additionally, we are super grateful to City Barbecue of Durham for providing us with catering for our design reviews and welcome events. Ops also organized our annual go karting event at VIR, which Owen won by pouring Dasani in my gas tank, as well as our annual Chanquet to celebrate a successful semester. Keep an eye out next semester for new merch and a fresh livery (Montucky Cold Snacks declined the opportunity to be our title sponsor so we are moving on to livery plan B).
Powertrain
Like Electrics, Powertrain started the semester focused on E95 with a full engine teardown. What started as an unfortunately routine head gasket replacement uncovered a bent con rod and piston rings that were on their way to becoming piston horseshoes. This meant our crate engine got the chance to turn her first few miles on the dyno. We ran into some setup issues early on, but after trying every combination of ignition coil and fuel injector to cylinder mapping, as well as learning what a CRIP test was, she fired up beautifully. With the switch to natural aspiration this year, a new top mounted restrictor and plenum were designed and manufactured. The clutch servo has been relocated to adjacent the engine now that the lack of turbo plumbing has freed up some space. Additionally, a new fuel tank has been designed to accommodate 100 Octane instead of E95 E85 this year. We’ve shortened up our final drive this year with a new 40 tooth driven sprocket to give us more torque on corner exit and to make victory donuts at MIS a bit easier to initiate.
Vehicle Dynamics
VD put in an impressively productive fall design cycle and is well in to manufacturing the bulk of components. Suspension points were finalized and new tabs were designed to reduce compliance. A new suspension arm force calculator was built and informed the design of the wheel assemblies, bearing carriers, and bellcranks. The turnbuckle suspension arms from last year were cut in favor of male rod ends to save weight. Center lock wheel assemblies were also re-designed to accommodate the new suspension geometry and the nut retaining method was improved to give us a shot at beating Guido’s pit stop times. A huge shout out to Ethan at Centric Iterations for graciously manufacturing our uprights this year. On the controls side, independent pedal rails and assemblies were designed to save weight and increase serviceability. The crew also got the chance to talk to FSAE legend Mike O’Neill to go over brake calculations and spec a pedal ratio, master cylinders, and brake pads. With nearly every part ready for manufacturing, a rolling car is right around the corner.
The fall semester was packed with all the design ingredients for a delicious finish in Michigan this season. 2025 is the time to make it happen. I’m nylocked in.
Happy New Year
-Cody
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