The method described in this presentation is just one way of pulling the build off, mostly based on what my team did. There is no doubt that there might be better ways. The purpose of this presentation was for the newbies to see how the various mechnicals come together, their relative proportions, sizes, positions, layouts, etc. Also, I shall carry out corrections and revisions from time to time, so that more information can be passed on effectively to successive BAJA aspirants.

1. Team STRATOS
BUILDING A BAJA BUGGY IN 40 STEPS

2. 1. SUCCESS AT BAJA= DEDICATED TEAM +
SMART CAPTAIN + HELPFUL FACULTY ADVISOR

3. 2. DIVIDE THE TEAM, RESEARCH, BRAINSTORM,
DISCUSS, DEBATE AND ARGUE

4. 3. MAKE A BASE PLAN AND THEN 3D CAD
WIREFRAME

5. 4. BUILD PROTOTYPE OF SPACE FRAME. ESP.
FOR FIRST TIMERS

6. 5. CAD MODELS AND ANALYSIS

7. 5A. PRELIMINARY AND FINAL MODELS

8. 6. OBTAIN A NICE AND TIDY WORKSHOP

9. 7. SET TABLE ACCURATELY AND MAKE
MARKINGS

10. 8. START FROM THE BASE WITH NECESSARY
MATERIALS

11. 9. FINALIZE AND SECURE BASE

12. 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

13. 11. ACCURATE EDGE PROFILES ARE CRUCIAL

14. 12. SPOT TALENTED WELDER(S), ENCOURAGE
SUFFICIENT TRAINING AND START WELDING

15. 12A. GOOD WELDS ARE THE SECRET OF A GOOD
CAR

16. 13. SCHEDULE WELL THROUGHOUT

17. 14. KEEP SPONSORS IN THE LOOP

18. 15. ENSURE FIT OF CRITICAL COMPONENTS

19. 16. COMPLETE FRAME

20. 16A. NOW BRING THE FRAME TO THE DESIRED
RIDE HEIGHT. HELPS IN SUSPENSION BUILD

21. 17. WORK ON SUB-COMPONENTS MUST BE
ATLEAST HALF WAY THROUGH

23. 18. ALSO ARRANGE FOR ALL ACCESSORIES

24. 19. START THE ASSEMBLY!

25. 20. FINISH CRITICAL COMPONENTS FIRST:
A-FRONT SUSPENSION

26. B-REAR SUSPENSION

27. C-HUBS

28. D-STEERING ASSEMBLY

29. E- DRIVETRAIN

30. F- BRAKE LINES, TIE RODS AND INNOVATIONS
(IF ANY)

31. 21. INSTALL THE OTHER ESSENTIALS: SEAT,
SAFETY KIT, ETC

32. 22. ELECTRICAL AND BODY PANELS ARE
OPTIONAL AT THIS STAGE

33. 23. TIME FOR THAT FIRST EVER TEST DRIVE!!

34. 24. DISCUSS IMPROVEMENTS NECESSARY

35. 25. STRIP DOWN ALL THE PARTS FOR PAINT
JOB. START BY SPRAYING RED OXIDE

36. 26. MAKE IMPROVEMENTS TO OTHER PARTS OF
THE CAR SEPARATELY.

37. 27. APPLY PRIMER ON THE FRAME

38. 28. MIX PAINT WITH THINNER APPROPRIATELY
AND TRY OUT

39. 29. NOW GIVE ATLEAST 2 COATS OF PAINT

40. 30. RE-ASSEMBLE THE CAR

41. 31. COMPLETE THE CAR TO THE MAXIMUM
EXTENT: BODY PANELS, INNOVATIONS, ETC

42. - 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

43. 32. RUN FIELD TESTS FOR ATLEAST A MONTH
(CRITICAL)

44. 33. MAKE YOUR COLLEGE COME TO LIFE AT 3AM

45. 34. HOPE THINGS FAIL HERE SO YOU CAN YOU
CAN BE SAFER ON RACE DAY

46. 35. TEST MORE AT TOUGHER PLACES.
Courtesy: Dirt Mania ATV dirt track, Kanakpura Road, Bengaluru

47. 36. HOPE MORE THINGS FAIL AT THE RIGHT
TIME

48. 37. REPAIR AND TEST EVEN MORE.

49. 38. GO BACK TO GARAGE. CLEAN UP, TOUCH UP

50. 39. SHIP TO RACE TRACK

51. 40. KEEP TOOLS AND SPARES HANDY AND
HOPE FOR THE BEST AT BAJA!!

52. IF THINGS DON’T WORK OUT, DON’T BE TOO
DISHEARTENED..

53. ..YOU MIGHT STILL GET TO WIN ANOTHER DAY!

54. 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.

55. 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.

56. MY BEST WISHES TO ALL FUTURE BAJA
ASPIRANTS!!
-Manish O.

57. THANK YOU!
Do give suggestions and/or comments to make this more helpful.