Design and Fabrication of IC Engine Powered Radio Control Car

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Jul 17, 2009

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Guest article by Srihari.B
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To fabricate the suspension arms to improve strength.

To fabricate a suitable body for the RC car.
1. Introduction: 1.1 Radio Control Car:
A radio-controlled car (R/C car) is a powered model car driven from a
distance using a radio control system. Inputs from joysticks (or a wheel
and a trigger) on a transmitter are sent to the car's onboard receiver. The
receiver interprets the radio signals and sends electrical pulses to the servo
and electronic speed controller, making the model turn its wheels and the
motor run.
http://www.meadinfo.org/2009/07/design-and-fabrication-of-ic-engine.html 1/22
RC Buggy (Scale 1:8)

Radio-controlled (or R/C) cars are usually categorized as either "toy" or
"hobby" grade. Remote-controlled vehicles differ from radio-controlled by
the presence of a wire cable connecting the transmitter and the car,
limiting their movement
Cars are powered by various sources. Electric cars are powered by small
but powerful electric motors and rechargeable nickel-cadmium, nickel
metal hydride, or lithium polymer cells. There are also brushed or
brushless electric motors. Most fuel-powered models use glow plug
engines, small internal combustion engines fueled by a special mixture of Ads by Google
nitro methane, methanol, and oil (in most cases a blend of castor oil and A Car Engine
synthetic oil). These are referred to as "nitro" cars.
About Car Race
Further these cars can be classified as Off-road and on-road models. Off-
road models, which are built with fully-functional off-road suspensions,
can be used on various types of terrain. In comparison, on-road cars,
which generally have a limited or non-existent suspension, are strictly
limited to smooth, paved surfaces
1.2 IC Engine Powered Car:
An R/C car can be powered by motors or engines. The cars that are
powered with engines are called as Nitro-powered RC car. They use
methanol as a basic fuel with a percentage of nitro methane as booster and
castor oil for lubrication.
Fuel-powered engines allow model cars to reach moderate speeds
unmodified. Maximum power is generally achieved at medium to high
speeds and a slightly slower throttle response than electrically powered
vehicles are to be expected. Electric motors effectively produce
instantaneous torque, where nitro engines, like full-sized gasoline engines,
take time for the engine to spool up and for the clutch to engage. Nitro-
(and fuel) powered cars may be refueled and returned to action in a few
seconds, as opposed to electrics needing to remove the body shell and
battery fasteners to replace a discharged battery. Nitro cars are completely
air cooled, and may be run continuously with no need to take breaks for
cooling down. Nitro cars tend to be larger than electric cars on average
1.3 Principle of Operation:
Radio-controlled cars use a common set of components for their control
and operation. All cars require a transmitter, which has the joysticks for
control, or in pistol grip form, a trigger for throttle and a wheel for turning,
and a receiver which sits inside the car. The receiver changes the radio
signal broadcast from the transmitter into suitable electrical control
signals for the other components of the control system. Most radio systems
utilize amplitude modulation for the radio signal and encode the control
positions with pulse width modulation. Upgraded radio systems are
available that use the more robust frequency modulation and pulse code
modulation. The radio is wired up to either electronic speed controls or
servomechanisms which perform actions such as throttle control, braking,
steering, and on some cars, engaging either forward or reverse gears.
Electronic speed controls and servos are commanded by the receiver
through pulse width modulation; pulse duration sets either the amount of
current that an electronic speed control allows to flow into the electric
motor or sets the angle of the servo. On the models the servo is attached to
at least the steering mechanism; rotation of the servo is mechanically
changed into a force which steers the wheels on the model, generally
through adjustable turnbuckle linkages. Servo savers are integrated into all
steering linkages and some nitro throttle linkages. A servo saver is a
flexible link between the servo and its linkage that protects the servo's
internal gears from damage during impacts or stress.
Belt Driven On-road Car (Scale 1:10)

Fuel powered models utilize a servo for throttle and braking control;
rotation of the servo in one direction will cause the throttle on the
carburetor to open, providing more air and fuel mixture to the internal
combustion engine. Rotation of the servo in the other direction causes
torque to be applied to a piece which causes friction with the braking
material. The brake is located on the driveshaft and stops only two wheels
on a two-wheel drive car and all four wheels on a four-wheel drive car.
The whole machine is divided into three major categories:
1) Engine
2) Chassis and Suspension
3) Control
2. Engine
2.1 Introduction
Engine
Most gas R/C models use a 2- or 4-stroke glow engine, sized specifically
for that model. Glow engines have a simple ignition system that uses a
glow plug rather than a spark plug so there’s no coil, magneto or points.
The glow plug is heated by a battery-operated glow starter. When fuel
enters the combustion chamber, it’s ignited by the heated glow plug and
with that, the engine springs to life, instantly gaining the momentum to
continue running after all the starter accessories are removed. The
engine’s carburetor supplies the fuel and air needed for combustion. It
has several adjustments. A rotating throttle arm controls the amount of
fuel and air that enters the combustion chamber. The high-speed needle
valve controls the mix or proportions of fuel vs. air at mid- to high-speeds.
The idle mixture screw is similar to the high-speed needle valve, except
that it controls the mix of fuel and air when the engine is only idling.
2.2 Glow plugs
Glow plugs
A gasoline combustion engine uses a spark plug to ignite the fuel-air
mixture within the compression chamber, so a glow or nitro engine uses a
small glow plug. Although the plug needs to be heated up using a glow
plug igniter initially, once the engine is running, the heat generated
within the combustion chamber keeps the plug glowing constantly and is
thus able to ignite the fuel-air mixture on each revolution.
To start a glow plug engine, a small direct current (around 1.5 volts) is
applied to the glow plug, initially heating the filament. The engine is then
spun from the outside to introduce fuel to the chamber. Once the fuel has
ignited and the engine is running, the electrical connection is removed.
Each combustion keeps the plug's filament glowing hot, allowing it to
ignite the next charge, thus sustaining the power cycle.
Technically a glow plug engine is similar to a diesel engine in that it uses
internal heat to ignite the fuel, but since the ignition timing is not
controlled by fuel injection (as in an ordinary diesel), or electrically (as in a
spark ignition engine), it must be adjusted by changing fuel/air mixture
and plug/coil design. A richer mixture will tend to cool the filament and so
retard ignition, slowing the engine. This "configuration" can also be
adjusted by using varying plug designs for a more exact thermal control.
2.3 Fuel
Glow engines cannot be operated with the same gasoline you get at a filling
station pump. They require a special fuel, called “glow fuel”. It contains
methanol as the base, with varying amounts of nitro methane to increase
the energy that the fuel can provide. Oil, pre-mixed into the fuel, lubricates
and protects the tiny engine as it pounds out amazing power. The mixture
of the fuel is 85% methanol and 15% castor oil.
2.4 Carburetor
Carburetor
Sitting at the front of the engine on top of the crankshaft is the
carburetor, which is the part of the engine that introduces the fuel into
the crankcase. The fuel / air mixture is ignited by a glow plug which is
screwed into the top of the cylinder head.
3. Chassis & Suspensions:
The chassis should be light in weight, strong and also able to accommodate
all the components. It can be made of aluminum or carbon graphite. The
chassis should bear the whole weight of the car. So it should be rigid and
also accommodate the other forces acting on it.
The basic components of a car are
1) a) Rear drive shaft or dog bone b) Front dog bone
2) Front and rear disk brakes.

3) Center bulkhead.
4) Fuel tank
5) Center differential and spur gear.
6) a) Rear chassis brace
b) Front chassis brace
7) Servo tray
8) Battery and receiver box
9) Rear shock tower. The shock tower has many different mounting holes
for both the shock and camber link.
10) Rear camber link – turnbuckle (adjustable)
11) Rear hub carrier.
12) Rear suspension arm.
13) Rear sway bar.
14) Rear CVD shaft.
15) Rear hub.
16) Rear differential housing, differential and rear bulk head.
17) Rear springs.
18) Rear shocks
Rear suspensions
Front steering and suspensions

19) Upper and lower pivot/pillow balls. They thread into both the upper
and lower A-arms. This gives you the ability to change camber.
20) Front CVD

21) Front lower suspension arm
22) Upper suspension arm - A-arm.
23) Front shock tower.
24) Front drive shaft or dog bone.
25) Steering knuckle.
26) Front hub.
27) Front sway bar.
28) Front differential, differential housing and bulkhead.
3.1 Suspensions
The main component of a suspension is its springs. Coil springs are used
commonly. These are usually placed around the damper housing to form a
spring-damper unit. A spring is an elastic device that resists movement in
its direction of work
The main job of the suspension system is the following,
1. Maintain the ride height
2. To provide damping
3. To give the best suspension travel for a typical car
4. To prevent the car from rolling
5. To protect the car and all its components

3.1.1 Ride Height
This refers to the clearance between the ground and the chassis, both at
the front and the back of the vehicle. The spring adjusters on the shock can
be adjusted (which are at the top of each shock spring) until the
appropriate height is achieved after the drop test. If you have an on-road
vehicle, you should place it on a flat hard surface, compress the suspension
a few times by pressing on the chassis and let it return to its normal
position
Deflection of different springs

3.1.2 Toe-In/Toe-Out
It is the angle of the front tires when viewed from above when the
suspension arms are level. If the fronts of the tires angle in, it is called
“toe-in” and if the fronts of the tires angle out, it is called "toe-out.” This is
adjusted by turning the steering rods - the rods that run between the front
hub and the steering linkage that is mounted on the chassis.
3.1.3 Camber
Camber is the angle of the tops of the tires when viewed from the front.
Negative camber is when the tops of the tires are angled towards the center
of the vehicle. Positive camber is where the tops of the tires are angled
away from the center of the vehicle. Positive camber is very rarely used, if
ever. A small amount of rear negative camber is helpful to increase traction
in the rear. Negative camber at the front will increase stability.
4. CHASSIS FABRICATION
Comparison with Fabricated Chassis (Left - Modified Chassis, Right -

Original Chassis)
4.1 Fabricated chassis
The chassis has very minimal flex and is very rigid. The chassis is hand
worked in a tincture shop and all the holes and the spur clearance and
starter box provisions are drilled to match with the required dimension to
suit the layout of the car.
The following alterations are made on the new chassis:

Ø Added material for extra strength at the corners
Ø Bent sides which will act as a bumper in one way and also reduces the
longitudinal torsion
Specifications Fabricated Chassis Readymade Chassis
Material Aluminum 6061 Carbon Graphite
Thickness 3mm 2mm
Mass 750gms 500gms
Length 392mm 392mm
Width 225mm 190mm
Maximum 12.2mm 7mm
thickness
Table 4.1 Comparison between the fabricated and readymade chassis
4.2 Method of Fabrication:
The raw material taken was Aluminium 6061 and of thickness 3mm.
Then the various processes that were done on the sheet were
1. Cutting and parting off : The chassis was cut to the required
dimension with the help of the readymade chassis
2. Drilling: The required holes for the mounting of the various
components were measured and then drilled on to the chassis
3. Slot Drilling: The slots for the flywheel for starting and stopping
the engine are also provided. It was machined using a hand drill
4. The corner bends were provided in order to prevent the flexing
and bending of the member
5. The slots were also given for the mounting of the servo motors in
position.
The fabricated chassis proved to withstand the various forces like the
vertical bending, Longitudinal torsion, lateral bending and Horizontal
lozenging.
5. STEERING MECHANISMS:
The steering mechanism of this on-road vehicle is totally unique where we

have eliminated all the ball and socket joints in order to make the
mechanism as well as the fabrication part a bit simpler.
Drag links with ball and socket joints

The challenge here was to eliminate all the joints with two or more degree
of freedoms and restrict it to one degree of freedom in two directions. The
idea was inspired from the universal joint. Usually the joints are made of
plastics. The material selection was also a challenging task since it has to
have the strength and functionality as that of the readymade one.
5.1 Steering Link Design
The objective of the design was to eliminate the ball and socket joint. So
the single member was split into three different components. The one was
a rod with external threads. The other member is to hold the joint and the
third member will have one rotational degree of freedom.
Steering Components
Stud
The component in Fig 5.1 is fastened with the stud and on the other end is
a freely rotating member which will be fastened with the hub on one end
and to the servo link on the other end. It will provide the two DOF and also
is easy to fabricate.
5.2 Steering Link Assembly
It bears some similarity with a universal joint but how ever the application
part is new!!! The brown member is a stud on which two brackets are
screwed into. Then the green member is a ‘free to oscillate’ kind of member
which will effectively allow both the degrees of freedom that a ball and
socket joint would do.
Steering Mechanism Assembly

For example the member on the left is oscillating along the XX axis then
the member on the right will oscillate along the YY axis thus satisfying the
conditions of a steering link.
Steering links
The links shown here will be substituted instead of the ball and socket
joints. The small member is the member that will move both in X and Y
directions and the bigger member is the coupling member.
Steering Link in the car

6. ENGINE: O.S. 18 TZ (S)-T
OS ENGINE
6.1 Specifications:
DISPLACEMENT: .183ci (3.008cc)
BHP: 2.27 at 31,761 rpm
TORQUE: 84.58 in.-oz. at 24,000 rpm
BORE: .629 in. (15.97mm)
STROKE: .590 in. (14.986mm)
PORTS: 5-port
Practical rpm: 3,000-34,000
CRANKSHAFT O.D.: .471 in. (11.963mm)
CRANKSHAFT I.D.: 305 in. (7.747mm)
CRANKSHAFT PIN: .175 in. (4.445mm)
PIPE: X12 Turbo
PLUG: O.S. Turbo P3
ENGINE TEMP: 230°F
EGT: 625°F
HEAD SHIMS: (1) .007 in., (1) .0035 in.
HEAD VOLUME: .21cc
POWER STROKE: .370 in. (9.398mm)
COMPRESSION RATIO(S): Trapped 7.89:1 Geometric 11.99:1
INDUCTION DURATION: 208 degrees
EXHAUST DURATION: 164 degrees
TRANSFER DURATION: 124 degrees
BOOST DURATION: 108 degrees

6.2 Port Configurations:
0 degree, 90 degree, 180 degree, 270 degree Port Configurations

The exhaust port is widest at the top to allow more exhaust gases to escape
quickly. The port in the sleeve very closely matches the shape and position
of the exhaust port in the engine block, and that allows exhaust to flow
much more smoothly. The Schnuerle ports are two separate ports on each
side of the cylinder, and there’s a vane cast into the transfer passage in the
block that matches the ports. A single boost port features moderate port
timing.
6.3 Dyno Tests:
Dyno test
Green Line: Peak torque 83.1 oz-in @ 25850 RPM torque—83.1 oz.-in.
Red Line: Peak Bhp 2.28 @ 30500 RPM
6.4 Advantages:
Oversize fins on the case dissipate heat to help keep engine temperatures
lower.
Five ports in the liner increase air flow for more power.
The rear bearing is 12 mm in diameter, which lessens vibration and allows
the engine to handle more torque.
A super-hot turbo P3 plug is included for better burn, more power and
improved fuel economy.
The 18TZ-TX version features a new compact recoil starter that's smaller
and lighter, making it easier to install.
7. Basic Components - Specifications:
Basic layout
Length: 431mm
End to end width: 310mm
Distance between wheel centers: 325mm
Ground clearance: 25mm
Diameter of wheel: 100mm
7.1 MECHANICAL COMPONENTS:
The following components are classified under the mechanical

components,
1. Chassis
2. Engine 3.0 cc (0.18TZ OS)
3. Air Filter
4. Exhaust manifold
5. Muffler
6. Clutch
7. Gear Box
8. Differentials
9. Front & rear hubs
10. Drive Shafts
11. Steering System
12. Disc Brake
13. Front & Rear – Lower & Upper Arms
14. Shock Absorbers

15. Fuel Tank (150ml)
7.1.1 Exhaust Muffler
Exhaust muffler with the engine

The exhaust muffler is an attachment along with the engine. It is tuned in
such a way as to reduce the exhaust pressure and hence the noise of the
engine to its minimum.
7.1.2 Clutch
Centrifugal clutch
The centrifugal clutch is an automatic clutch. The spring tension
determines is engagement and disengagement. The clutch engages at
2000- 3000 RPM. The material it is made of is an alloy of brass, so that it
can withstand high temperatures and also it has a good coefficient of
friction also. The flywheel is a solid aluminium block to store energy
during the non-power strokes.
7.1.3 Gear box:
Gear box assembly
The gear is made of Nylon material

It is mounted at the center of the chassis and gives power to the
two drives that goes to the front and the rear wheels
It has a gear ratio of 1:2.4 and 1:1.5
2 speed No of teeth: 1st speed: 50, 2nd speed: 42
Brake: Disc type
Material: Fiber glass
7.1.4 Differential with casing
Differential and casing

The RC car is a four wheel drive with a central drive and two differentials
on both the sets of wheels. The material of the bevels used in the
differential is a heat treated steel. The basic function of the differential is
to control the speed of the wheels rotation while encountering a turn. The
differential is lubricated with crease and it is sealed with a plastic casing.
The drive shaft is a dog bone shaft and is connected with the differentials
using a CV joint. From the differentials the power is transmitted to the
wheels using the dog bone shafts.
7.1.5 Suspension system:
The suspension system of the RC car is a wish bone type of suspensions

with all the upper and lower arms made of plastic. The suspension is again
an individual suspension.
Suspension components
Spring type oil damped
Spring material: carbon steel
Free length: 35mm
Pitch: 5mm
No of turns: 7
Damping is provided using the suspension oil.Damping is needed to
absorb the energy associated with suspension travel. That suspension
travel can be induced by bumps, or lateral or longitudinal acceleration.
Without damping, the magnitude of the suspension movement would
never stop increasing, leading to a very humorous situation. In terms of
energy, damping absorbs most of the energy the car receives as it moves,
unlike springs stores the energy, and release it again
7.2 ELECTRICAL & ELECTRONIC COMPONENTS:
The electrical and electronic components basically aids in the control of

the steering and the throttle. The electronic components in the RC car are,
1. Crystal Transmitter
2. Battery pack
3. Servo motors
4. Radio Pistol
7.2.1 Crystal transmitter:
The crystal transmitter transmits AM radio waves which is received by the
receiver and controls the servo motors. The frequency of the transmitter is
24.045 MHz
Transmitter
Battery pack for the radio box (4 numbers)
1.5 v AA size batteries
7.2.2 Servos
Servomotors
One for the steering and the other for throttle and breaks
HS311 Servo Specs:

Speed: 0.19 sec/60 degrees at 4.8V
Speed: 0.15 sec/60 degrees at 6.0V
Torque: 42.00 oz-in at 4.8V
Torque: 51.00 oz-in at 6.0V
Length: 1.60" (41mm)
Width: 0.80" (20mm)
Height: 1.40" (37mm)
Weight: 1.5oz (43g)
Servo motor
7.2.3 Radio:
Pistol radio controller
Pistol grip radios contain the transmitter. The trigger is used for the
acceleration and braking. The steering is controlled by the steering wheel
kind of control. The pistol grip radio is a three way control as it controls
acceleration, braking and steering
Pistol grip radio

AM Transmitter/Receiver
27.045MHz band
Output power: <0.75 mW
Current Drain (w/servos): approximately 250mA
BODY
The body of the RC car is important in the way of protecting the engine
and other critical parts from damage due to accidents. It will also in some
way help in the aerodynamics of the car and it gives aesthetics to the car.
The body of the car is tinkered from a 3mm thick mild steel sheet and is
welded to obtain the shape of the sedan.
The shape of the body was achieved by sheet metal working and welding of
the ends.
9. Work progress in phases:
Phase -1 Body fabrication, Welding, Painting
Phase -2 Basic work, Chassis modification, Parts matching, Suspension

mounting
Phase -3 Engine mounting, Engine assembly, Engine alignment, Final

testing
10. TEST RESULTS
The results obtained in the fabrication of the RC car can be compared with
the actual readymade model and the various deviations and accuracies can
be known. The results are tabulated as that of the specifications of a real
car.
The following results were obtained during the final testing,
Price - Rs.16,618
Length: 431mm
End to end width: 310mm
Distance between wheel centers: 325mm
Ground clearance: 25mm
Diameter of wheel: 100mm
Turning Circle: 400mm
Kerb Weight: 5 Kgs
Engine: 3cc OS engine
Peak Bhp 2.28 @ 30500 RPM
Peak torque 83.1 oz-in @ 25850 RPM torque—83.1
Steering Type – Bell crank mechanism with universal joints
Suspensions – Double wish bone suspensions
Brake – transmission disc brake
Top Speed – 60 KMPH
Fuel tank capacity – 150 ml
Steering control: High torque Servo motor:
Throttle and braking control: Servo motor
1st Gear engagement: 0-5000 RPM
2nd Gear engagement: 5000-35000 RPM
Braking: 50-0 KMPH in 3 seconds
Acceleration: 0-50 KMPH in 3.5 seconds
Courtesy and References:
Mr. Murarie Kumar. Personal and professional support

OS 18 TZ Engine manual
www.towerhobbies.com
http://www.rc-truckncar-tuning.com/RC-Nitro-Engine-
Carburetor.html
http://www.raptortechnique.com/enginetuning_beginner.htm
http://www.redrc.net/2007/01/team-associated-launch-rc8-first-
pictures/
http://www.rchobby.co.uk/radio_controlled_cars.html
http://www.rc-airplane-world.com/model-airplane-engines.html
http://www.easyrc.com/index.html
http://www.easyrc.com/cars-trucks/carstrucks4.html
IIT Bombay, Techfest 08, FTGP tutorial.
Tribute
The successful completion of this project is a glittering hallmark of

academic achievement and I am greatly indebted to scores of individuals
who have contributed their mite for the jubilant finish of this project work.
I would like to express my sincere thanks to the following people, who in
one way or the other helped or inspired me in the success of this project.
Mr.Murarie kumar, Mentor, guide and sponsor of this project

Dr. P.V.Mohanram, Head of Department of Mechanical Engineering
Mr. B.Giriraj, Faculty, Department of Mechanical Engineering
Sowrirajan K, Team member
Rakesh Narayanan, Team member
Ramani S, Team member
Ragunathaprabhu S, Team member
About The Author

Srihari.B
Founder : Team RHTP
Webpage:- http://rhtp.in
email id:- teamrhtp@rhtp.in
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9/4/2018 Design and Fabrication of IC Engine Powered Radio Control Car

Jul 17, 2009

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Guest article by Srihari.B

1. Material Properties of S355 Steel - An Overview

2. 1.4301 Stainless Steel - An Overview

To fabricate the suspension arms to improve strength.

RC Buggy (Scale 1:8)

Belt Driven On-road Car (Scale 1:10)

The basic components of a car are

1) a) Rear drive shaft or dog bone b) Front dog bone

2) Front and rear disk brakes.

Front steering and suspensions

20) Front CVD

5. To protect the car and all its components

Deflection of different springs

Comparison with Fabricated Chassis (Left - Modified Chassis, Right -

4.1 Fabricated chassis

The following alterations are made on the new chassis:

Table 4.1 Comparison between the fabricated and readymade chassis

4.2 Method of Fabrication:

The steering mechanism of this on-road vehicle is totally unique where we

Drag links with ball and socket joints

Steering Mechanism Assembly

Steering Link in the car

BOOST DURATION: 108 degrees

0 degree, 90 degree, 180 degree, 270 degree Port Configurations

The following components are classified under the mechanical

14. Shock Absorbers

Exhaust muffler with the engine

Gear box assembly

The gear is made of Nylon material

Differential and casing

7.1.5 Suspension system:

The suspension system of the RC car is a wish bone type of suspensions

The electrical and electronic components basically aids in the control of

HS311 Servo Specs:

Speed: 0.15 sec/60 degrees at 6.0V

Torque: 42.00 oz-in at 4.8V

Torque: 51.00 oz-in at 6.0V

Length: 1.60" (41mm)

Width: 0.80" (20mm)

Height: 1.40" (37mm)

Weight: 1.5oz (43g)

Pistol radio controller

Pistol grip radio

9. Work progress in phases:

Phase -1 Body fabrication, Welding, Painting

Phase -2 Basic work, Chassis modification, Parts matching, Suspension

Phase -3 Engine mounting, Engine assembly, Engine alignment, Final

10. TEST RESULTS

The following results were obtained during the final testing,

Acceleration: 0-50 KMPH in 3.5 seconds

Courtesy and References:

Mr. Murarie Kumar. Personal and professional support

The successful completion of this project is a glittering hallmark of

Mr.Murarie kumar, Mentor, guide and sponsor of this project

About The Author

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