Andrew Ajirogi

Ben Aldern

John Odlum

Johnny Chang
Table of Contents
Introduction .................................................................................................................................................. 3
Members ................................................................................................................................................... 3
Formula SAE (FSAE) ................................................................................................................................... 3
Background ............................................................................................................................................... 4
Project Design ............................................................................................................................................... 5
Materials ................................................................................................................................................... 5
Flexure Design, actuator lever and mount ............................................................................................... 5
Actuator lever and mount......................................................................................................................... 7
Electrical .................................................................................................................................................... 8
Testing ........................................................................................................................................................... 9
Results ....................................................................................................................................................... 9
 Introduction

Members
Andrew Ajirogi
is a senior
John Odlum is a
mechanical
senior mechanical
engineer. As
engineer. He is now
the FSAE
an unofficial member
technical
of FSAE with his
director, he is
design of the mount
knowledgeable
and clamp for the
of all the
actuator.
systems in the
car and system integration.

Ben Aldern is a Johnny Chang is a

senior mechanical senior mechanical
engineer. He is the engineer and FSAE
FSAE team chassis and
principal and composites lead.
electrical lead.

Formula SAE (FSAE)

Formula SAE is an international competition organized by the Society of Automotive Engineers where
college students design, manufacture and test a formula style car. The car built by UC Berkeley’s
Formula SAE uses a 2001-2003 Suzuki GSX-R600 engine that has a sequential gearbox. The gears can
only shift in a sequential order (up or down without passing through neutral.) Shifts are actuated by the
rotation of a lever at the gearbox.
 Figure 1: Red arrow (push) is a downshift. The blue arrow indicated a pull, up shift. The gearbox is different for first gear
where the driver will have will downshift (push) to get to first gear and from first gear only pull half to return to neutral

Background
The old shifting system on the car was actuated by a lever mounted to the left of the driver. See Figure
1. This lever was attached to a push-pull cable which ran the length of the car to the transmission. When
a shift was needed, the driver would remove his or her left hand from the wheel, grab the lever, and
push or pull it. Pushing caused an extension of the cable at the shifting spline, causing a downshift.
Pulling retracted the cable, making the car up shift. The system was fully mechanical, but required the
driver’s left hand to be off the wheel.

This was problematic in a few specific ways. The time taken between when the shift was needed to
when it was actuated was somewhat slow due to the driver’s need to move his or her hand. The lever
also proved to be difficult to actuate at certain critical times. On a Formula SAE competition course with
many turns, frequent shifting is required to maximize performance. If a shift was needed during a turn
the driver would have to make the turn with one hand on the steering wheel or simply wait until out of
the turn and lose time while the engine was in a bad RPM range. As well, toward the end of a race the
driver’s arms would be tired from steering, causing increased difficulty in actuating the shift and longer
delays between when the shift was needed and when it was actuated. Both situations would lead to a
decrease in overall performance.

The goal of this project was to install a paddle shifting system to address these issues and eliminate the
detriment of the push-pull system to overall performance in a race. With paddle shifting, the driver
would be able to actuate a shift without removing his or her hand from the wheel, increasing control at
every point in the race. As well, the amount of force required by the driver to actuate the shift is
minimized to reduce the strain of a race. This would ideally lead to faster shift times, a decrease in
weight, and reduction in part numbers by removing the long cable. The system is designed with
increased performance, lighter weight, and simplicity as the driving parameters. When finalized, it
would allow the driver to actuate a shift almost instantaneously without losing any control of the car.
 Project Design
The new system is designed with the above considerations in mind. Behind the steering wheel, paddles
attached to steel flexures were installed within the reach of the driver’s fingertips. On each side of the
flexure, a momentary rocker-type switch was installed such that when the flexure was pressed towards
the wheel by the driver, the switch would be activated. The flexures acted as a restoring force, returning
to the original position after the driver deformed them to actuate the shift. Once the switch is activated,
it sends a signal to the vehicle’s engine control unit (ECU). The ECU then determines which type of shift
was called for based on which switch was activated. The ECU then sends current through a relay to an
electric solenoid that actuates the shift. The current creates a magnetic field within the solenoid, causing
the metal arm in the center to extend (downshift) or retract (up shift) depending on the direction of the
current. See Figure 2.

(a) (b) (c)

Figure 2: (a) Solidworks CAD of the actuator in the extended position (downshift) (b) In the neutral position (wait for signal)
(c) is the retracted position (upshift)

Materials
-FlatShifter electric solenoid

-Steel flexures

-MoTeC M400 engine control unit (ECU)

-Steel actuator mount

-Aluminum actuator clamp

-Electrical relays and wiring

-Aluminum shifter spline

Flexure Design
Design Specifications:
- The movement of the lever on the switch dictates how much the flexure must distort in order to
achieve a successful shift. This was measured to be approximately 3mm at the point of contact of the
switch lever.
- For driver comfort the amount of reaction force from pressing the lever should not exceed 3
pounds.
 - The flexure must also be robust, due to the cyclical loads that are imposed on it. Therefore the
stress in the flexure must not exceed the endurance limit stress of 4130 normalized steel (at 870
degrees Celsius)

The mesh for the stress region was set to fine (triangles of length 0.158 inches). The mesh size was
determined through inspection of mesh sensitivity, or the amount the stress in a region changes due to
mesh size with the same force and constraints. The mesh sensitivity converged at the element size
previously mentioned. See Figure 3

Figure 3: A finer mesh is seen by the smaller triangles on the left.

There is a stress concentration at the corner after the switch mount; this is assumed to be non
representative due to the sharp edge in the CAD. The manufactured part has a fillet and mitigates this
stress riser. The rest of the stress plot shows stress 50ksi and below, which is right around the
endurance limit for 4130 steel. See Figure 4.

Figure 4: The arrow shows where the stress concentration in the flexures
Figure 5: Deflection in the region near the switch lever is transitioning from green to yellow (indicted by red arrow) which is
the 2.9-3mm region, meeting the design specification.

A two pound force is applied at the back face of the flexure where the paddle will be bonded. The front
face of the flexure is fixed to simulate a bolted connection to the rear face of the steering wheel. The
front of the flexure is fixed as an approximation to the bolted connection between the steering wheel
and the flexure. This approximation is valid because the clamping force from the bolts connecting the
steering wheel to the flexure is much larger than the force applied to the flexure. See Figure 5.

Actuator lever and mount

Before choosing an actuator we assessed the requirements of the transmission. To engage the next gear
the selector shaft needs to be rotated approximately 15 degrees for up shifts and downshifts and
requires a minimum of 78 lb-inches to move through this motion. This torque was measured with a
strain gauge attached to the cockpit lever of the old push-pull system. All of the force that went into the
lever was applied through this strain gauge and with precise measurements of the levers involved we
were able to calculate the torque at the selector shaft.

With this knowledge we set out to choose an actuator and assessed pneumatic, hydraulic, electric gear,
and electric solenoid systems. We chose the electric solenoid system because of the low parts count,
simplicity, availability, and cost.

Electric solenoids produce much of their force at the end of the stroke and thus it’s necessary to use the
entire stroke. The lever at the selector shaft with the old system was 1.25” long and, with a rotation of
15 degrees, far too short for the electric actuator with a stroke of 1”. We made a new 4” lever and
packaged were careful to package it in a way that would not interfere with any existing parts.
Electrical
The electrical system utilized the Motec M400 that the team already had. The solenoid was purchased
separately from a company who makes a similar product for disabled motorcyclists. The circuit was
relatively simple and easy to integrate into the system. Figure 6 shows how a upshift is completed.

Figure 6: The wiring diagram shows how a driver gets an upshift. Pulling the upshift paddle sends a signal to the ECU and the
ECU sends a signal to a relay that powers the actuator.
 Testing
In order to prove the new system, we ran the car with data acquisition with several relevant sensors
including gear position, switch input status, output status, and engine RPM. These datasets allowed us
to tune the system parameters to achieve the fastest and most reliable shift times.

Figure 7: This picture shows a snapshot of the paddle shifter system working. For videos, please visit
http://www.youtube.com/user/calfsae

Results
Below are two graphs showing data gathered while running with the old push-pull lever and with the
new paddle shifters. The shift shown from the old system was executed in 204 milliseconds and the
paddle shifters executed the shift in 170 milliseconds, 16.5% faster. More importantly, the driver was
able to keep his hands on the steering wheel during both up- and downshifts, allowing him to maintain
better control of the car.
 Figure 8: Push-pull system downshift in 204 milliseconds

Figure 9: Paddle shifter system downshift in 170 milliseconds

 8 7 6 5 4 3 2 1
REVISIONS
ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/25/2011 ATA

D ITEM
D
PART NUMBER DESCRIPTION QTY.
NO.
PADDLE-FLEXTURE-SWITCH
1 paddle-flexture 1
ASSEM

2 QuickRelease_v01_TT QUICK RELEASE 1

4

RACETECH STEERING
3 Racetech240mmWheel_ 1
2 WHEEL
v02_TT

Racetech Quick
4 QUICK RELESE SPLINE 1
Release Spline
3X 8 1
5 FRONT CLUTCH MOUNT
5 2012-DR-03-000 1
ASSEM
3 6 27 AN3 BOLT 1
7 2012-DR-04-000 CLUTCH LEVER ASSY 1
8 AN3_Nut AN3 NUT 7
C 3X 9 C
9 number10_bolt #10 SHCS 0.75" 6
7

6
3X 9 3X 8

B B

DETAIL A
SCALE 1 : 1

TEAM CAL SIMRACEWAY

TITLE:

Paddle Shifter Assembly

A A
UNLESS OTHERWISE SPECIFIED
TOLERANCES: NAME DATE
ANGULAR: 2DEG
ONE PLACE DECIMAL 0.030" 3D ATA 11/25/2011 SIZE PART NUMBER DRAW
TWO PLACE DECIMAL 0.01" REV
SolidWorks Student License THREE PLACE DECIMAL 0.005" 2D ATA 11/25/2011 E 2012 Steering Subassem AA

Academic Use Only MATERIAL:

CHK ATA 11/25/2011 SCALE: 1:2
DO NOT
SCALE DRAWING SHEET 1 OF 1
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/22/2011 ATA

D D

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 flexure FLEXTURES 1
2 number2_bolt 2-56x0.75" bolt 4
3 paddles Paddles 2
4 Switch SS-5GL13T Limit Switch P/N: SS-5GL13T 2
2 5 90545A003 2-56 Hex Nut 4

C C

B B

TEAM CAL SIMRACEWAY

TITLE:
A
A
PADDLE-FLEXTURE-SWITCH ASSEM
UNLESS OTHERWISE SPECIFIED
TOLERANCES: NAME DATE
5 ANGULAR: 1DEG DRAW
ONE PLACE DECIMAL 0.030" 3D ATA 11/22/2011 SIZE PART NUMBER
REV
TWO PLACE DECIMAL 0.01"
THREE PLACE DECIMAL 0.005" 2D ATA 11/22/2011 B paddle-flexture AA+
MATERIAL: DO NOT SCALE
CHK ATA 11/22/2011 SCALE: 1:1 DRAWING
SHEET 1 OF 2
8 7 6 5 4 3 2 1

SolidWorks Student License

Academic Use Only
 8 7 6 5 4 3 2 1

D D

BOND PADDLES
WITH HYSOL 9309 (X2)

C C

0.2 0.2

B B
0.9

0.9
A
A

TEAM CAL SIMRACEWAY

SIZE PART NUMBER DRAW
REV

B paddle-flexture AA+
DO NOT SCALE
SCALE: 1:1 DRAWING
SHEET 2 OF 2
8 7 6 5 4 3 2 1

SolidWorks Student License

Academic Use Only
 8 7 6 5 4 3 2 1
REVISIONS
ZONE REV. DESCRIPTION DATE APPROVED
NOTES:
AA INITIAL RELEASE 11/21/2011 ATA
1. WATERJET PART, .030" sheet
2. DEBUR ALL EDGES 8.149
3. DRILL OUT HOLES (IF NECESSARY)
4. ALL DIMENSIONS ARE SYMMETRICAL TO THE LEFT

DOWN 89° R 0.070

DOWN 89° R 0.070

D SIDE OF PART D

UP 89° R 0.070
UP 89° R 0.070

UP 90° R 0.070
UP 90° R 0.070
3X
0.
25
7

1.986
9
C
0.08 UP 90° R 0.070
C
4X
0.067

0.342

UP 90° R 0.070

1.208

1.973

B B

TEAM CAL SIMRACEWAY

TITLE:
A FLEXTURES A
UNLESS OTHERWISE SPECIFIED
TOLERANCES: NAME DATE
ANGULAR: 1DEG DRAW
ONE PLACE DECIMAL 0.030" 3D ATA 11/21/2011 SIZE PART NUMBER
REV
TWO PLACE DECIMAL 0.01"
THREE PLACE DECIMAL 0.005" 2D ATA 11/21/2011 B flexure AA+
MATERIAL: DO NOT SCALE
AISI 4130 Steel, normalized at 870C CHK ATA 11/21/2011 SCALE: 1:1 DRAWING
SHEET 1 OF 1
8 7 6 5 4 3 2 1

SolidWorks Student License

Academic Use Only
 8 7 6 5 4 3 2 1
REVISIONS
NOTES: ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/27/11 JLC
1. WATERJET PART (CAN BE CUT
AND BELT SAND TO SIZE)
2. DEBUR ALL EDGES
D D

2x
R1
.0

C C
1.0

0 .3
0.071 2 xR 2.4

B B

TEAM CAL SIMRACEWAY

TITLE:

A UNLESS OTHERWISE SPECIFIED

Paddles A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D JLC 11/27/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License THREE PLACE DECIMAL 0.005" 2D JLC 11/27/2011 A paddles AA+
MATERIAL:
Academic Use Only 6061-T6 (SS) Aluminum CHK JLC 11/27/2011 SCALE: 1:1 DO NOT SCALE DRAWING SHEET 1 OF 1

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/21/2011 ATA

D D
0.125 A

A
ITEM
NO. PART NUMBER DESCRIPTION QTY.
1 2012-DR-03-001 CLUTCH MOUNT CYLINDER 1

1.500
FRONT CLUTCH MOUNT,
2 2012-DR-03-002 1
STEERING SIDE
3 2012-DR-03-004 CLUTCH PIVOT 1
4 2012-DR-03- FRONT CLUTCH MOUNT 1
003_paddleshift

C C

TOP OF DR-03-001
AND DR-03-002 FLUSH 2

1
0.560

B 4 B
2.000
0.940

BOTTOM OF DR-03-001 TEAM CAL SIMRACEWAY

AND DR-03-002 FLUSH
TITLE:
A
A
CLUTCH ASSEMBLY
UNLESS OTHERWISE SPECIFIED
TOLERANCES: NAME DATE
ANGULAR: 1DEG DRAW
ONE PLACE DECIMAL 0.030" 3D ATA 11/21/2011 SIZE PART NUMBER
REV
TWO PLACE DECIMAL 0.01"
THREE PLACE DECIMAL 0.005" 2D ATA 11/21/2011 B DR-03-000 AA+
MATERIAL: DO NOT SCALE
CHK ATA 11/21/2011 SCALE: 1:1 DRAWING
SHEET 1 OF 1
8 7 6 5 4 3 2 1

SolidWorks Student License

Academic Use Only
 8 7 6 5 4 3 2 1
REVISIONS
NOTES: ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/21/2011 ATA
1. DEBUR ALL EDGES

D D

1. 0.035
18

C C

1.250

2.000
B B

TEAM CAL SIMRACEWAY

TITLE:

A UNLESS OTHERWISE SPECIFIED

CLUTCH MOUNT TUBE A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D JR 10/25/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License THREE PLACE DECIMAL 0.005" 2D ATA 11/21/2011 A 2012-DR-03-001 AA+
MATERIAL:
Academic Use Only MILD STEEL CHK ATA 11/21/2011 SCALE: 1:1 DO NOT SCALE DRAWING SHEET 1 OF 1

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
NOTES: ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/25/2011 ATA
1. WATERJET PART
2. DEBUR ALL EDGES
3. DRILL OUT ALL HOLES
D D

0
25
1.
0
20
0.160

0.
3X
C C
1.975

B 2.241 B

TEAM CAL SIMRACEWAY

TITLE:

FRONT CLUTCH MOUNT, STEERING SIDE

A UNLESS OTHERWISE SPECIFIED A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D ATA 11/25/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License THREE PLACE DECIMAL 0.005" 2D ATA 11/25/2011 A 2012-DR-03-002 AA+
MATERIAL:
Academic Use Only MILD STEEL CHK ATA 11/25/2011 SCALE: 1:1 DO NOT SCALE DRAWING SHEET 1 OF 1

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
NOTES: ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/25/2011 ATA
1. WATERJET PART
2. DRILL OUT ALL HOLES
3. DEBUR ALL EDGES
D D

0
25
1.
0.160

0
20
0.
3X
C C

0
25
0.
2.5

B B

2.25

TEAM CAL SIMRACEWAY

TITLE:

A UNLESS OTHERWISE SPECIFIED

FRONT CLUTCH MOUNT A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D ATA 11/25/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License THREE PLACE DECIMAL 0.005" 2D ATA 11/25/2011 A 2012-DR-03-003_paddleshift AA+
MATERIAL:
Academic Use Only MILD STEEL CHK ATA 11/25/2011 SCALE: 1:1 DO NOT SCALE DRAWING SHEET 1 OF 1

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
NOTES: ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/21/2011 ATA
1. DRILL ONE HOLE AND FLIP PART TO DRILL
THE OTHER HOLE, DO NOT DRILL IN ONE
SETUP
2. WATERJET PART
D 3. DEBUR ALL EDGES D
0.
18
8 0.649
TH
RU

0.500
0.250
C C

0.250

B B

0.250

TEAM CAL SIMRACEWAY

TITLE:

A UNLESS OTHERWISE SPECIFIED

CLUTCH PIVOT A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D ATA 11/21/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License THREE PLACE DECIMAL 0.005" 2D ATA 11/21/2011 A 2012-DR-03-004 AA+
MATERIAL:
Academic Use Only MILD STEEL CHK ATA 11/21/2011 SCALE: 1:1 DO NOT SCALE DRAWING SHEET 1 OF 1

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/25/2011 ATA

D D

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 2012-DR-04-001 SHIFT LEVER 1
2 2012-DR-04-002 CLUTCH LEVER CABLE RESTRAINT 1

HOLE ALIGNED TO CENTERLINE

OF 2012-DR-04-001

2
C C

B B

2.6

1
TEAM CAL SIMRACEWAY
TITLE:
A
A
CLUTCH LEVER ASSY
UNLESS OTHERWISE SPECIFIED
TOLERANCES: NAME DATE
ANGULAR: 1DEG DRAW
ONE PLACE DECIMAL 0.030" 3D ATA 11/25/2011 SIZE PART NUMBER
REV
TWO PLACE DECIMAL 0.01"
THREE PLACE DECIMAL 0.005" 2D ATA 11/25/2011 B 2012-DR-04-000 AA+
MATERIAL: DO NOT SCALE
SS - 304 CHK ATA 11/25/2011 SCALE: 1:1 DRAWING
SHEET 1 OF 1
8 7 6 5 4 3 2 1

SolidWorks Student License

Academic Use Only
 8 7 6 5 4 3 2 1
REVISIONS
ZONE REV. DESCRIPTION DATE APPROVED
NOTES:
AA INITIAL RELEASE 11/25/2011 ATA
1. PROFILE IS CNC BENT
2. TOTAL UNBENT LENGTH : 14.85"

RU
3. HOLES ARE DRILLED OUT AFTER 0.2

TH
BENDING

0
19
D D

0.188

0.
6.188

0.2
C C
0.018

5
37
0.

2.0

B B

TEAM CAL SIMRACEWAY

TITLE:
A
A
SHIFT LEVER
UNLESS OTHERWISE SPECIFIED
TOLERANCES: NAME DATE
ANGULAR: 1DEG DRAW
ONE PLACE DECIMAL 0.030" 3D ATA 11/25/2011 SIZE PART NUMBER
REV
TWO PLACE DECIMAL 0.01"
THREE PLACE DECIMAL 0.005" 2D ATA 11/25/2011 B 2012-DR-04-001 AA+
MATERIAL: DO NOT SCALE
SS - 304 CHK ATA 11/25/2011 SCALE: 1:1 DRAWING
SHEET 1 OF 1
8 7 6 5 4 3 2 1

SolidWorks Student License

Academic Use Only
 8 7 6 5 4 3 2 1
REVISIONS
NOTES: ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/25/2011 ATA
1. TOP AND BOTTOM SLOTS ARE FOR
MATING TO DR-04-001 FOR WELDING

5
D D

37
0.
0.018

C C
2X 1 6°

2X 0.375

1.0

2.0
U
T HR BE
. 2 50 F TU
0 RO
TE
C EN
B B

TEAM CAL SIMRACEWAY

TITLE:

A UNLESS OTHERWISE SPECIFIED

CLUTCH LEVER CABLE RESTRAINT A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D ATA 11/25/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License THREE PLACE DECIMAL 0.005" 2D ATA 11/25/2011 A 2012-DR-04-002 AA+
MATERIAL:
Academic Use Only SS - 304 CHK ATA 11/25/2011 SCALE: 1:1 DO NOT SCALE DRAWING SHEET 1 OF 1

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
BOM Table
ITEM PART NUMBER DESCRIPTION QTY.
NO.
1 2012-EN-01-ENGINE-MOCKUP Engine 1
2 mounting piece Clamp to engine mount 1
3 mounting bracket swivel side Actuator clamp part 1 1
4 mounting bracket Actuator clamp part 2 1
5 7806K62 Thrust bearing 2
6 2012-DR-05-008 Rod end 1
D D
7 kliktronic body Actuator 1
8 new spline Spline lever 1
9 90576A115 M6x1 nut 1
10 97135A215 1/4-28 nut 1
11 92235A242 M6x1 bolt 2
12 91290A264 M5x1 bolt 2
13 .25-28x1.5 for clamp 1
14 10-32x1.5 for clamp 2

C C

7 2 14

B B

13

1
6

2 5
10 3
11

12
9
TEAM CAL SIMRACEWAY
TITLE:

A Mount mechanism A
UNLESS OTHERWISE SPECIFIED
TOLERANCES: NAME DATE
ANGULAR: 2DEG
ONE PLACE DECIMAL 0.030" 3D SIZE PART NUMBER DRAW
BA 11/27/2011 REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License THREE PLACE DECIMAL 0.005" 2D BA 11/27/2011 E rear drawing A-02

Academic Use Only MATERIAL:

CHK JLC 11/27/2011 SCALE: 1:1
DO NOT
SCALE DRAWING SHEET 1 OF 2
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1

D D

C C

B B

RIght View

TEAM CAL SIMRACEWAY

TITLE:
2012 Full Car Model
A Mount mechanism (fully assembled) A
UNLESS OTHERWISE SPECIFIED
TOLERANCES: NAME DATE
ANGULAR: 2DEG
ONE PLACE DECIMAL 0.030" 3D SIZE PART NUMBER DRAW
BA 11/27/2011
TWO PLACE DECIMAL 0.01" REV
SolidWorks Student License THREE PLACE DECIMAL 0.005" 2D BA 11/27/2011 E rear drawing A-02

Academic Use Only MATERIAL:

CHK JLC 11/27/2011 SCALE: 1:1
DO NOT
SCALE DRAWING SHEET 2 OF 2
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
NOTES: ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/27/11 ATA
Machine Center and through holes before cutting
in two
NSF 10/32 Screw
D
Clearance 1.383 NSF 10/32 Screw Tapped D

9
0.600 1.96

2.769
C C

0.250

0.375
0.431
46°

0.381
1.863
B B
3.246
0.500

TEAM CAL SIMRACEWAY

TITLE:
Mount Clamp
A UNLESS OTHERWISE SPECIFIED A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D JEO 11/27/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License
THREE PLACE DECIMAL 0.005" 2D JEO 11/27/2011 A mount clamp AA+
Academic Use Only
MATERIAL:
Aluminum CHK ATA 11/27/2011 SCALE: 1:1 DO NOT SCALE DRAWING SHEET 1 OF 2

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/27/2011 ATA
Notes:
1. Jig in car to fit
D D

C C

8°

2.193
31.6
B B
0.999

TEAM CAL SIMRACEWAY

TITLE:

Mounting Weld Locations

A UNLESS OTHERWISE SPECIFIED A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D BA 11/27/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License
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Academic Use Only
MATERIAL:
Steel CHK ATA 11/27/2011 SCALE: 1:2 DO NOT SCALE DRAWING SHEET 1 OF 2

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/27/11 ATA

D D

C C
TRUE 0.402

0.500
TRUE 0.500

3.250
B B

TEAM CAL SIMRACEWAY

TITLE:
Mounting Tubes
A UNLESS OTHERWISE SPECIFIED A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D BA 11/22/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License
THREE PLACE DECIMAL 0.005" 2D JEO 11/27/2011 A Tubes AA+
Academic Use Only
MATERIAL:
Steel CHK ATA 11/27/2011 SCALE: 1:1 DO NOT SCALE DRAWING SHEET 1 OF 2

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
NOTES: ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/27/2011 ATA
1. Waterjet Profile
2. Drill Hole
3. Debur Edges
D D

2.052

0
0.21
C C
2.437

2.129
B B

0.150

TEAM CAL SIMRACEWAY

TITLE:
Mountig Piece
A UNLESS OTHERWISE SPECIFIED A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D BA 11/22/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License
THREE PLACE DECIMAL 0.005" 2D JEO 11/27/2011 A mounting piece AA+
Academic Use Only
MATERIAL:
Steel CHK ATA 11/27/2011 SCALE: 1:1 DO NOT SCALE DRAWING SHEET 1 OF 2

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
NOTES: ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/21/2011 ATA
1. DEBUR ALL EDGES AFTER MACHINING

D D

0.
27
5 0.113

C C

0.500

0.750
B B

TEAM CAL SIMRACEWAY

TITLE:

A UNLESS OTHERWISE SPECIFIED

CLUTCH MOUNT BOSS A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D JO 11/1/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License THREE PLACE DECIMAL 0.005" 2D ATA 11/21/2011 A 2011-DR-09-001-AA AA+
MATERIAL:
Academic Use Only Mild Steel CHK ATA 11/21/2011 SCALE: 2:1 DO NOT SCALE DRAWING SHEET 1 OF 1

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/28/11 ATA

D ITEM NO. PART NUMBER DESCRIPTION QTY. D

1 2012-DR-06-001 Purchased Part 1
2 new spline 1

1 2

C C

3.33
Make lever arm and spline parallel

B B

0.350

TEAM CAL SIMRACEWAY

TITLE:

spline lever
A UNLESS OTHERWISE SPECIFIED A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D JLC 11/27/11 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
SolidWorks Student License THREE PLACE DECIMAL 0.005" 2D JLC 11/27/11 A new spline assem AA+
MATERIAL:
Academic Use Only CHK JLC 11/27/11 SCALE: 1:2 DO NOT SCALE DRAWING SHEET 1 OF 1

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
REVISIONS
NOTES: ZONE REV. DESCRIPTION DATE APPROVED
AA INITIAL RELEASE 11/27/2011 ATA
1. Waterjet profile
2. drill hole

D D

0.236

C C

3.334
3.713

B B

0.200
1.257
TEAM CAL SIMRACEWAY
TITLE:
New Spline Arm
A UNLESS OTHERWISE SPECIFIED A
TOLERANCES: NAME DATE
ANGULAR: 2DEG DRAW
ONE PLACE DECIMAL 0.030" 3D JEO 11/27/2011 SIZE PART NUMBER REV
TWO PLACE DECIMAL 0.01"
THREE PLACE DECIMAL 0.005" 2D JEO 11/27/2011 A new spline AA+
SolidWorks Student License
Academic Use Only
MATERIAL:
Steel CHK ATA 11/27/2011 SCALE: 1:1 DO NOT SCALE DRAWING SHEET 1 OF 2

8 7 6 5 4 3 2 1