SEAN HORNCHEK PROJECT PORTFOLIO

On top of being in charge of suspension design, manufacturing, and testing. I lead the completion of all vehicle powertrain guarding and SAE rule-specific component design/manufacturing. 

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This included several frame members that needed to be added to the vehicle to reach certain SAE rules specified for driver safety.  The Solidworks pipes/tubes tools were used to export bend radii and mitering dimensions. Driver ergonomics and ease of exit/entry were considered. 

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Powertrain guarding for the driveshaft and CV axles were made, following SAE rulebook for minimum material strength and finger guarding. The design was done using Solidworks sheet metal toolbox. Sheet metal parts were plasma cut/industrial shears and bent using bending brake tools. A full transmission housing was created to comply with rules and make the vehicle safe to race.

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Sheet metal skid plates were designed to cover and protect sensitive areas of the underbelly of the vehicle. 

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Various sheet metal parts were designed to be manufactured from steel sheets to be folded and used as mounting brackets.

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Preliminary testing resulted in a cracked engine mount. The team and I removed the initial design and created a much thicker engine plate that was reinforced by shorter/direct tubing that proved to be reliable.

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One other member and I also completed the cost event for the competition, recording all vehicle-related costs and creating presentations to reduce future costs.

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All capstone members and I created final presentations/writeups for our undergraduate program as well as for the SAE competition.

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Being one of the four members of this incredibly new and small Baja SAE team was extremely difficult and rewarding. I was able to have my hands on nearly every aspect of the vehicle.