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BAJA SAE SERIES
BAJA SAE INDIA 2010Rule Book
Ver 1.1_May 2009
C/OSAEINDIA,NATRIP
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11.Overview..............................................................................................................................................8
11.1BajaSAEIndiaProgramObjective.............................................................................................................8
11.2CompetitionGoals.....................................................................................................................................8
11.3TheBajaSAESeries...................................................................................................................................8
11.4OfficialAnnouncementsandCompetitionInformation............................................................................9
12.BajaSAERulesandOrganizerAuthority..............................................................................................9
12.1RulesAuthority..........................................................................................................................................9
12.2RulesValidity.............................................................................................................................................9
12.3RulesCompliance......................................................................................................................................9
12.4UnderstandingtheRules...........................................................................................................................10
12.5ParticipatingintheCompetition...............................................................................................................10
12.6ViolationsofIntent....................................................................................................................................10
12.7RighttoImpound.......................................................................................................................................1012.8GeneralAuthority......................................................................................................................................10
13.Eligibility..............................................................................................................................................10
13.1IndividualParticipantRequirements.........................................................................................................10
13.1.1StudentStatus........................................................................................................................................11
13.1.2SocietyMembership...............................................................................................................................11
13.1.3Age............................................................................................................................ 11
13.1.4DriversLicense......................................................................................................................... 11
13.1.5LiabilityWaiverandInsurance.................................................................................................... 11
13.1.6OnlineRegistrationRequirements................................................................ 11
13.1.7OnsiteRegistrationDocumentCopiesrequired.11
13.2FacultyAdvisor.......................................................................................................................... 12
14.EligibilityVehicles..................................................................................................................... 12
14.1StudentCreated................................................................................................................................... 12
14.2ProfessionalFabricationLimits.................................................................................. 12
14.3KitVehiclesProhibited............................................................................................... 12
14.4PrefabricatedSubassemblies................................................................................................................ 12
14.5TopTenTeamsDesignComparisonRequirement..................................................................................12
14.6Redesign/DesignComparisonDocument............................................................................. 13
14.7DuplicateDesigns.......................................................................................................... 13
15.Registration..................................................................................................................................... 13
15.1MaximumEntriesperUniversity...................................................................................................... 13
15.2RegistrationDeadline............................................................................................................................... 13
20.GeneralDesignRequirements.......................................................................................................... 14
20.1VehicleDesignObjective...........................................................................................................................14
20.2VehicleConfiguration................................................................................................................................1420.2.1MaximumVehicleDimensions.............................................................................................................. 14
20.3AllTerrainCapability............................................................................................................................... 14
21.RequiredEngine................................................................................................................................. 14
21.1EngineEligibility....................................................................................................................................... 15
21.2EligibleTeamsReceivingNewEngines................................................................................................. 15
21.2.1EngineShipmentoutsidetheU.S.&Canada........................................................................................ 15
21.3PurchasingofAdditionalBriggs&StrattonEngines.............................................................................. 15
21.4EngineRequirementandRestrictions.......................................................................................................15
21.4.1ReplacementParts............................................................................................................................. 15
21.4.2PistonRings............................................................................................................................................15
21.4.3IntakePorts........................................................................................................................................ 15
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31.2.4RollHoopOverheadMembers(RHO)................................................................................................. 27
31.2.5LowerFrameSideMembers(LFS)...................................................................................................... 27
31.2.6SideImpactMembers(SIM)................................................................................................................ 28
31.2.7FrontBracingMembers(FBM).......................................................................................................... 28
31.2.8RollHoopBracing(FAB)....................................................................................................................... 28
31.2.9RHO/FBMGusseting...29
31.2.10ButtJoints........................................................................................................................................... 29
31.2.11WeldConfirmationChecks.................................................................................................................. 30
31.2.12FinalJudgment.................................................................................................................................. 31
31.3HeadRestraint......................................................................................................................................... 31
31.4DriverHeadClearance..............................................................................................................................32
31.4.1HeadClearanceMinimum............................................................................................................... 32
31.5RollCage&BracingMaterials............................................................................................................... 3231.5.1RollCageSpecificationSheetRequired........................................................................................... 33
31.6
Roll
Cage
Padding..................................................................................................................................
33
31.7SharpEdgesonRollCageProhibited.................................................................................................. 33
31.8BoltedRollCages................................................................................................................................... 33
31.9DriverSeat33
32.Cockpit........................................................................................................................................... 34
32.1DesignObjective........................................................................................................................................34
32.2DriverExitTime...................................................................................................................................... 34
32.3Firewall..................................................................................................................................................... 34
32.3.1FrontorMidengineCars...................................................................................................................... 34
32.4BodyPanels.............................................................................................................................................. 34
32.5BellyPan................................................................................................................................................... 35
32.6LegandFootShielding............................................................................................................................. 35
32.7KillSwitches............................................................................................................................................. 35
32.7.1KillSwitchType................................................................................................................................. 35
32.7.2KillSwitchLocationsandOrientation.............................................................................................. 36
32.7.3KillSwitchWiring.............................................................................................................................. 36
32.8FireExtinguisherSizeandLocation..................................................................................................... 36
32.9Throttle.................................................................................................................................................. 36
32.9.1ThrottleExtensions.............................................................................................................................. 36
33.DriverRestraint................................................................................................................................ 37
33.1MinimumFiveStrapSystemRequired.................................................................................................. 37
33.1.1ReleaseMechanism............................................................................................................................ 37
33.1.2SafetyHarnessExpiration.................................................................................................................... 37
33.2ShoulderHarness..................................................................................................................................... 37
33.2.1VerticalLocation................................................................................................................................... 37
33.2.2HorizontalLocation............................................................................................................................... 37
33.2.3HarnessAttachmentPoints................................................................................................................. 38
33.2.4RedirectionofHarnessWebbing........................................................................................................ 38
33.3Lap&AntiSubmarineBelts................................................................................................................... 38
33.3.1SpecifiedLap&AntiSubmarineBeltsMounting................................................................................ 38
33.4Belts...................................................................................................................................................... 39
33.5ArmRestraints....................................................................................................................................... 39
33.5.1ArmRestraintInstallation............................................................................................................... 39
33.5.2ArmRestraintExpiration.................................................................................................................. 39
33.5.3InstallationsGeneral.......................................................................................................................... 40
34.BrakingSystem...................................................................................................................................40
34.1FootBrake............................................................................................................................................ 40
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34.2IndependentBrakeCircuits.................................................................................................................... 40
34.3BrakeLight........................................................................................................................................... 40
34.4Brake(s)Location.......................................................................................................................... 40
34.5CuttingBrakes....................................................................................................................................... 40
35.FuelSystemandFuel................................................................................................................. 40
35.1SystemLocation...................................................................................................................................... 40
35.1.1RemovableFuelTank.................................................................................................... 41
35.2FuelTank............................................................................................................................................... 41
35.3FuelLines................................................................................................................................................ 41
35.4SpillPrevention....................................................................................................................................... 41
35.4.1SpillPreventionMounting.................................................................................................................. 41
35.4.2SpillPreventionDraining...................................................................................................................... 41
35.4.3SpillPreventionDrainMaterial.......................................................................................................... 41
35.4.4FillerCap.42
35.5
Splash
Shields.........................................................................................................................................
42
35.6Fuel............................................................................................................................................................42
36.Steering,SuspensionandFloatationSystems.................................................................................. 43
36.1Wheelstops.43
36.2TieRodProtection..........................................................................................43
36.3AdjustableRodEnds....................................................................................................................................43
36.4HandleBarSteering...43
37.Fasteners....................................................................................................................................... 43
37.1Fasteners............................................................................................................................................... 4337.1.1LockWireProcedureDetail............................................................................................................. 43
37.2FastenerGradeRequirements............................................................................................................. 44
37.3ThreadExposure...................................................................................................................................... 45
37.4SocketHeadCapScrews...................................................................................................................... 45
37.5UnmarkedFasteners/ShopManufacturedFasteners........................................................................... 45
37.6Singleshearconnections..46
37.6.1TieRods..46
37.6.2BallJoints..46
38.Guards......................................................................................................................................... 46
38.1PowertrainGuards................................................................................................................................. 46
38.1.1SideShields........................................................................................................................................ 47
38.2FactoryStockGuards............................................................................................................................. 48
39.DriverEquipmentRequirements........................................................................................................ 48
39.1Helmet,NeckSupport/Collar&Goggles.............................................................................................. 48
39.2Clothing................................................................................................................................................. 49
40.RulesClarificationandProtests....................................................................................................... 50
40.1TechnicalQuestions................................................................................................................................. 50
40.2Protests.............................................................................................................................................. 50
40.2.1PreliminaryReviewRequired........................................................................................................... 50
40.2.2CauseforProtest............................................................................................................................. 50
40.2.3ProtestFormatandForfeit.......................................................................................................... 50
40.2.4ProtestPeriod............................................................................................................................. 51
40.2.5Decision..................................................................................................................................................51
41.CompetitionProceduresandRegulationGeneral....................................................................... 51
41.1DriversMeetings....................................................................................................................... 51
41.2PreinspectionOperationProhibited...................................................................................................... 51
41.3GovernorSetting.................................................................................................................................... 51
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41.4CompetitionFuelSupply.......................................................................................................................... 51
41.4.1Refueling.............................................................................................................................................. 51
41.5EngineandDrivetrainInspection......................................................................................................... 51
41.6EngineRecallOption............................................................................................................................... 52
41.7PitRules................................................................................................................................................ 52
41.7.1VehicleMovementWalkingPaceRequired...................................................................................... 52
41.7.2TeamWorkArea................................................................................................................................ 52
41.7.3VehiclesinthePits.......................................................................................................................... 52
41.7.4OccupancyRestrictions......................................................................................................................... 52
41.8DrivingRestrictions................................................................................................................................ 53
41.9Loopholes............................................................................................................................................ 53
41.10Penalties............................................................................................................................................ 53
42.RulesofConduct............................................................................................................................... 53
42.1Sportsmanship.................................................................................................................................... 53
42.2
Alcohol
and
Illegal
Material.................................................................................................................
53
42.3Parties................................................................................................................................................ 54
42.4TrashCleanup..................................................................................................................................... 54
42.5SiteCondition.......................................................................................................................................... 54
43.SpectatorRules................................................................................................................................. 54
43.1General.................................................................................................................................................. 54
43.2AlcoholicBeverages.............................................................................................................................. 54
43.3AccessRestrictions................................................................................................................................. 54
43.4Children................................................................................................................................................... 54
43.5RemovalofSpectators........................................................................................................................... 54
44.UnsafePractices&Conduct.............................................................................................................. 55
45.Miscellaneous.................................................................................................................................. 55
45.1DriverEquipment................................................................................................................................. 55
45.2PracticeArea....................................................................................................................................... 55
46.SafetyTeamResponsibility............................................................................................................ 55
51.TechnicalInspection......................................................................................................................... 56
51.1TechnicalInspectionPass/Fail50Points......................................................................................... 56
51.1.1InspectionStickers.............................................................................................................................. 5851.1.2TechnicalInspectionSheetPreinspectionRequired........................................................................ 58
51.1.3AsapprovedCondition..................................................................................................................... 58
52.Staticeventsandrequiredreportstotal300points........................................................................ 59
52.1EngineeringDesign............................................................................................................................... 59
52.1.1DesignReport 100Points................................................................................................................. 59
52.1.2DesignReportFormat...................................................................................................................... 59
52.1.3DesignReportPageLimit................................................................................................................. 59
52.1.4DesignReportDeadlineandSubmission......................................................................................... 59
52.1.5Design100 Points............................................................................................................................. 60
52.2CostEvent............................................................................................................................................ 60
52.2.1CostReport10Points......................................................................................................................... 60
52.2.2CostReportElectronicFormat......................................................................................................... 61
52.2.3PenaltyforLateorNonSubmission................................................................................................ 61
52.2.4CostJudgesAuthority.................................................................................................................... 62
52.2.5PrototypeCost40points................................................................................................................ 62
52.2.6CostAdjustmentForm...................................................................................................................... 62
52.3Presentation50Points.................................................................................................................... 62
52.3.1PresentationObjective..................................................................................................................... 62
52.3.2PresentationFormat.......................................................................................................................... 62
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52.3.2.1Projectionequipments...63
52.3.3PresentationScoring......................................................................................................................... 63
53.DynamicEventsTotal700Points....................................................................................................63
53.1Acceleration100Points..................................................................................................................63
53.1.1AccelerationObjective...................................................................................................................... 63
53.1.2AccelerationProcedure................................................................................................................... 63
53.1.3AccelerationPenalties.................................................................................................... 63
53.1.4AccelerationScoring......................................................................................................................... 63
53.2TractionEvent100Points............................................................................................................. 64
53.2.1HillClimbingObjective..........................................................................................................................64
53.2.2HillClimbingProcedure.........................................................................................................................64
53.2.3HillClimbingEventPenalties................................................................................................................64
53.2.4HillClimbingScoring.............................................................................................................................64
53.3ManeuverabilityEvents100points..........................................................................................................66
53.3.1
Maneuverability
Objective.................................................................................................................
66
53.3.2ManeuverabilityProcedure............................................................................................................... 66
53.3.3ManeuverabilityPenaltyDefaultValues.......................................................................................... 66
53.3.4ManeuverabilityTimeLimit............................................................................................................ 66
53.3.5ManeuverabilityScoring..................................................................................................................... 66
53.4Endurance400Points........................................................................................................................... 67
53.4.1EnduranceObjective......................................................................................................................... 67
53.4.2EnduranceGeneralDescription......................................................................................................... 67
53.4.3EnduranceStarting........................................................................................................................... 67
53.4.4EnduranceCommandFlags......................................................................................................... 67
53.4.5EnduranceStalledorDisabledVehicles........................................................................................... 68
53.4.6EnduranceRepairs............................................................................................................................. 68
53.4.7EnduranceEventPenaltyDefaultValues........................................................................................... 68
53.4.8EnduranceScoring........................................................................................................................... 69
53.5Tiebreakers............................................................................................................................................. 70
APPENDIX:RollCageSpecificationSheet71
CONTACTS..72
ANNEXURE CODEOFCONDUCT..73
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SECTION1
GENERALINFORMATION
11.Overview
TheSAEMiniBajaCompetitionoriginatedattheUniversityofSouthCarolinain1976,underthedirectionof
Dr.JohnF.Stevens.Sincethenthecompetitionhasgrowntosixcompetitions:threeinNorthAmericaandone
eachinBrazil,KoreaandSouthAfricawithover500entries. Withthegrowthoftheseries,corporationshave
cometorecognizethatstudentswithBajaSAEontheirresumesarepremiercandidatesfortheirengineeringpositions.
Fromthe2007CollegiateDesignSeries,SAEannouncedthenameofMiniBajacompetitionsforrugged,single
seat,offroadrecreationalvehiclesasBajaSAE.ThischangebroughtthenameoftheoffroaddesigneventsintoconsistencywiththatofthewellknownFormulaSAEdesigncompetitionsforautocrossvehicles.Duringthesameyear,underthedirectionofDr.PawanK.Goenka(formerSAEINDIAPresident)andtheconvenership
ofDrK.CVora(Secretary,SAEIndia)BAJASAEINDIA,themaidenBAJASAEINDIASerieswasconductedatthe
NATRAX (National Automotive Test Tracks) facility of NATRIP (National Automotive Testing and R&D
InfrastructureProject),Pithampur,MadhyaPradesh,inDecember2007.Theeventwitnessed itssecondyear
inJanuary2009atNATRAX.
11.1BajaSAEINDIAProgramObjective
Baja SAE INDIA is an intercollegiate engineering design competition for undergraduate and graduateengineeringstudents.Theobjectofthecompetitionistosimulaterealworldengineeringdesignprojectsand
theirrelatedchallenges. Eachteam iscompetingtohave itsdesignacceptedformanufacturebyafictitious
firm. Thestudentsmustfunctionasateamtodesign,build,test,promoteandcompetewithavehiclewithin
the limits of the rules, also to generate financial support for their project and manage their educational
priorities.
11.2CompetitionGoals
Each teams goal is to design and build a prototype of a rugged, single seat, offroad recreational vehicle
intended for sale to the nonprofessional weekend offroad enthusiast. The vehicle must be safe, easily
transported,easily maintained and fun todrive. Itshould be able tonegotiaterough terrain inall typesof
weatherwithoutdamage.
11.3TheSAEBajaSeries
TheBajaSAESeriesconsistsofsevencompetitions. ThreecompetitionsareheldinNorthAmericaunderthe
sponsorshipofSAE:
BajaSAEAlabamaHostedbyAuburnUniversity
BajaSAEOregonHostedbySAEOregonSection
BajaSAEWisconsinHostedbySAEMilwaukeeSection
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Baja SAE competitions held in Africa, Asia and South America are associated with SAE, but organized and
sponsoredbytheirlocalhosts:
BajaSAEBrazilSponsoredandhostedbySAEBrazil.
BajaSAEKoreaSponsoredandhostedbyYeungnamUniversity.
BajaSAESouthAfricaSponsoredbySasolandhostedbytheUniversityofPretoria.
BajaSAEIndiaSponsoredandHostedbySAEINDIA&conductedatNATRAX,Pithampur.
All Baja SAE competitions have open registration policies and accept teams of university students from any
country.BajaSAE IndiawillacceptteamsonlyfromAsiafortheyear2010.Somesectionsofrulesgoverning
BajaSAEeventsheldoutside India arespecific to thosecompetitions. Suchvariationsarepublishedon the
individualwebsites.
11.4OfficialAnnouncementsandCompetitionInformation
Teams are required to read the articles posted on the Baja SAE India homepage (http://bajasaeindia.org)
published by SAE India and the other organizing bodies. Teams must also be familiar with all official
announcementsconcerningthecompetitionsandruleinterpretationsreleasedbytheBajaSAEIndiaTechnical
Committee.TheofficiallanguagefortheBajaSAEIndia2010EventisHindiandEnglish.
12.BajaSAEIndiarulesandorganizingauthority
12.1RulesAuthority
TheBajaSAEINDIArulesaretheresponsibilityoftheBajaSAEINDIAtechnicalcommitteeandareissuedunder
the authority of the SAE India. Official announcements from the Baja SAE INDIA technical committee, SAEIndiaortheotherBajaSAE INDIAorganizersshallbeconsideredpartofandshallhave thesamevalidityas
theserules.Ambiguitiesorquestionsconcerningthemeaningorintentoftheseruleswillberesolvedbythe
SAEIndiaTechnicalCommittee,SAEIndiaorbytheindividualcompetitionorganizersasappropriate.
Generalqueriesmaybeaddressedtoinformation@bajasaeindia.org.
12.2RulesValidity
The Baja SAE India Rules posted on the Baja SAE INDIA website and dated for the calendar year of the
competitionaretherulesineffectforthecompetition. Rulesetsdatedforotheryearsareinvalid.
12.3RulesCompliance
ByenteringaBajaSAEINDIAcompetition,theteam,membersoftheteamasindividuals,facultyadvisorsand
otherassociatedpersonnelagreetocomplywith,andbeboundby,theserulesandallruleinterpretationsor
procedures issued or announced by SAE India, the Baja SAE India Technical Committee and the other
concerned organizing bodies. All team members, faculty advisors and other associated representatives are
requiredtocooperatewith,andfollowallinstructionsfrom,competitionorganizers,officialsandjudges.
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12.4UnderstandingtheRules
Teamsareresponsibleforreadingandunderstandingtherulesineffectforthecompetitioninwhichtheyare
participating. Thesectionandparagraphheadingsintheserulesareprovidedonlytofacilitatereading;they
donotaffecttheparagraphcontents.
12.5ParticipatingintheCompetition
Team members as individuals, faculty advisors and other representatives of a registered college who are
presentonsiteatacompetitionareconsideredtobeparticipating inthecompetition fromthetimethey
arrive at the event site until they depart the site at the conclusion of the competition or earlier by
withdrawing.
12.6ViolationsofIntent
Theviolationoftheintentofarulewillbeconsideredaviolationoftheruleitself. Questionsabouttheintent
ormeaningofarulemaybeaddressedtotheBajaSAEIndiaTechnicalCommittee,TechnicalInspectorsorSAE
India.
12.7RighttoImpound
SAE India and the other competition organizing bodies reserve the right to impound any onsite registered
vehicle at any time during a competition for inspection and examination by the organizers, officials and
technicalinspectors.
12.8GeneralAuthority
SAE Indiaandthecompetitionorganizingbodiesreservetherighttorevisethescheduleofanycompetition
and/orinterpretormodifythecompetitionrulesatanytimeandinanymannerthatis,intheirsolejudgment,
requiredfortheefficientoperationoftheevent.
13.Eligibility
13.1 Individual Participant Requirements Eligibility is limited to undergraduate and graduate students to
ensurethatthisisanengineeringcompetitionratherthanarace.Individualmembersofteamsparticipatingin
thiscompetitionmustsatisfythefollowingrequirements:
13.1.1StudentStatus
Team members must be enrolled as a degree seeking undergraduate or graduate student in a college or
university. Team members who have graduated during the last seven (7) month period prior to the
competitionremaineligibletoparticipate.
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PLEASEBRINGYOURORIGINALDRIVERSLICENSE,PHOTOI.D./PASSPORT,SAEMEMBERSHIPCARDASWELLAS
YOURMEDICALINSURANCECARDTOONSITEREGISTRATION.
13.2FacultyAdvisor
Each team is expected tohave aFaculty Advisorappointedby theuniversity/college.TheFacultyAdvisor is
expectedtoaccompanytheteamtothecompetitionandwillbeconsideredbycompetitionofficialstobethe
officialuniversity/collegerepresentative.FacultyAdvisorsmayadvisetheirteamsongeneralengineeringand
engineeringprojectmanagementtheory,butmaynotdesignanypartofthevehiclenordirectlyparticipatein
thedevelopmentofanydocumentationorpresentation.Additionally,FacultyAdvisorsmayneitherfabricate
norassembleanycomponentsnorassistinthepreparation,maintenance,testingoroperationofthevehicle.
FacultyAdvisorsarenotallowedtoparticipateduringtechnicalinspectionordesignpresentations.Theteam
captainorotherdesignatedmembersoftheteammustdoallthepresenting.InbriefFacultyAdvisorsmay
notdesign,buildorrepairanypartofthevehicle.
14.EligibilityVehicles
14.1StudentCreated
Thevehicleandassociateddocumentationmustbeconceived,designedandfabricatedbytheteammembers
without direct involvement from professional engineers, faculty or professionals in the offroad and racing
communities. Proof of location of manufacture may be required to be furnished by the teams onsiteupon
beingsoaskedforbytheofficials.
14.2
Professional
Fabrication
Limits
Vehicles, which have been professionally fabricated, may be penalized or even disqualified from the
competition. The decision of the organizers in this regard will be final. The registration fee would NOT be
returnedinsuchcase.Onlythoseteamswhosemanagementgivesanundertakingtoallowtheteamstouse
theworkshopfacilitieswouldbeallowedtoparticipate,withoutexception.Technical Inspectorswillconduct
surprisevigilancechecksinvariouscolleges,wheretheteamsaresupposedtofabricatetheirvehicles.
14.3KitVehiclesProhibited
Vehiclesfabricatedfromakitorpublisheddesignsareineligibletocompete.
14.4PrefabricatedSubassemblies
Theserulesdonotexcludetheuseofprefabricatedormodifiedsubassemblies.Extensiveuseofreadymade
subassembliesmayinvokepenalties.
14.5Top10TeamsDesignComparisonRequirement
TeamswithvehiclesthatfinishedinatoptenpositioninanyofthepreviousyearsBajaSAEIndiacompetitions
areclassifiedashavingcreatedasuccessfuldesign.Teamsthatcreatedsuchsuccessfulvehiclesarerequired
toprovideacomparisonoftheircurrentdesignwiththeirpreviousyearsdesignevenifthecurrentdesignis
entirelynew.Aspartofthedesignevent,thejudgeswillevaluatethecomparisondocumentationofthetop
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tenteams.Teamrepresentativesmustbepresentduringthecomparisontodiscussthedesignchanges.Ifthe
judgesfindthatthedesignchangesare(A)notsignificant,(B)notsupportedbyadetailedanalysisor(C)have
notbeensufficientlydocumented,thenapenaltyofuptoonehundred(100)pointsmaybeassessedagainst
the design score. The modifications must, in the opinion of the designjudges, represent a rethinking and
redesign of one or more significant vehicle systems. Modifications are defined as, but not limited to: New
frameand/orrollcagedesign,newdrivetraindesignorarrangement(gearratiochangesareNOTconsidered
asdrivetrainmodifications),newsuspensiondesign,driverergonomicsandcontrols.
14.6Redesign/DesignComparisonDocument
The redesign/design document may be in the form of either, or both, (A) posters or (B) report. The
documentationshouldbeayeartoyearcomparisonofthemajorstructureand/orsystemsofthevehicleand
mayconsistofany, or all,of the following, supported by appropriatecaptions: (1)plans(2)drawingsor (3)
photographs.Designchangestocorrectfailuresofthepreviousdesignshouldbeaccompaniedbyathorough
analysisofwhythefailureoccurredandthetheoreticaldatasupportingthenewdesign,etc.
14.7DuplicateDesigns
TeamsareremindedthattheobjectiveofBajaSAEIndiaistoprovidestudentswithadesignchallengethatwill
enhance their engineering and engineering project management skills. Participating teams must be able to
demonstratetheirengineeringknowledgeeitherbydesigningavehiclefromscratchorbymakingsignificant
changestoapreviouslyenteredvehicle.If twocollegesbringstwovehiclesthatthedesignjudges,intheirsole
opinion,findtobeeitheridentical,ortoexhibitonlyinsignificantdifferences,thenthecarswillbetreatedasa
single entry with a duplicate car for parts. In such case only one car will be evaluated and permitted to
competeinthedynamicevents.
15.Registration
TeamsarerequiredtoregisterattheBAJASAEINDIAWebsite.Alltheupdateswouldbeputuponlineanditis
thesoleresponsibilityoftheteamtocheckforupdates.
15.1MaximumEntriesperCollege
Acollegecanhaveanynumberofteams, subject toapproval for finalparticipation from theBajaSAE India
Secretariat.
15.2RegistrationDeadlinesandfees
RegistrationfeewouldbecollectedindifferentstagesaspertheFlowChartattached.VirtualBAJAparticipants
wouldberequiredtopayRs.25,000/ andphysicalBAJAparticipantswouldberequiredtopayRs.50,000/
altogether. TheprocessisevidentfromthefollowingFlowChart,whichalsoincludesthetentativedeadlines.
RegistrationfeesareNOTrefundable.
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Section
2
Vehicle
Requirements
and
Restrictions
20.GeneralDesignRequirements
Acollegecanhaveanynumberofteams, subject toapproval for finalparticipation from theBajaSAE India
Secretariat.
20.1VehicleDesignObjective
Thevehicledesignshouldbeattractivetoconsumersbecauseofitsvisualappearance,performance,reliability
and ease of operationandmaintenance. It should also be manufacturableusing predominantly semiskilled
labor
and
standard
machine
tools.
Safe
operation
must
be
an
essential
consideration
in
your
design.
20.2VehicleConfiguration
Thevehiclemusthavefour(4)ormorewheelsnotinastraightline.Three(3)wheeledvehiclesareprohibited
from thecompetition.The vehicle mustbe capableof carryingone (1)person190.3cm (63) tallweighing
113.4kg(250lb).
20.2.1MaximumVehicleDimensions
Width:162.56cm(64in)atitswidestpoint(thewidestpointofthevehicleandnotnecessarilythewheeltrack
width)with thewheels pointing forwardatstaticride height.Vehiclesexceeding thisdimensionwillnot be
allowedtoruninanydynamicevent.Agonogodevicetocheckthisdimensionmaybemadeavailableby
theorganizers.
Length:Unrestricted,butseenotebelow.
NOTE: Teams should keep in mind that Baja SAE India course at Pithampur is designed for vehicles with
maximumdimensionsof64inwidthby108inlength.
20.3AllTerrainCapability
Thevehiclemustbecapableofsafeoperationoverrough land terrain including obstructions suchas rocks,
sand,jumps,logs,steepinclines,mudandshallowwaterinanyorallcombinationsandinanytypeofweatherincludingrain,snowandice. Thevehiclemusthaveadequategroundclearanceandtraction.
21.RequiredEngine
LombardiniLGA34011hpengine
FromthebeginningoftheBajaSAEIndiaseries,Lombardinihasgenerouslyprovidedenginestoparticipating
teamswithoutcharge.Thiscompetitionseasonaswell,LombardinihasagreedtoprovideenginestotheBaja
teams.Ateamhowever,paysonlyforshipping&handlingoftherequiredengines.Theteamsmaybeaskedto
collecttheirenginesfromspecifiedlocations.Also,theteamsneedtoarrangeallthetransitrequirementsas
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requiredbytheTransportationAuthorities,attheirown.Allsuchnotificationswouldbemadeavailableonthe
BAJAWebsite,www.bajasaeindia.org.
21.1EngineEligibility
TeamswillbeeligibletoreceiveanewLombardiniengineineverysecondcompetitionseasoninwhichthey
participate. Enginesareallocatedonthebasisofoneenginepervehiclepertwoseasonsofparticipation.
Example1:TeamsthatreceivedanewLombardiniengineforthe2007competitionseasonandcompetedin
Bajaevent(s)in2008and2009willbeeligibletoreceiveanewengineforthe2009competitionseason.
Example2:Ateamthatreceivedanewenginein2007,butdidnotcompeteinaBajaeventuntil2008and
doesnotcompeteagainuntil2011,willonlybecomeeligibletoreceiveanenginein2012.
21.2EligibleTeams ReceivingNewEngines
Registered&approvedteamsthatareeligibletoreceiveanewenginemustcompletetheengineorderform
onlineatwww.bajasaeindia.org.Detailswillbeputuponlineafterthefinalevaluationandselectionprocess.
Eligibleteamswillhavetobearthecostofshipping.
21.3PurchasingofAdditionalLombardiniEngines
TeamsmaypurchaseadditionalLombardiniLGA340enginesdirectlyfromthecompany. Thereisnospecial
discountorpresetpurchasepriceforadditionalengines.
21.4EngineRequirementsandRestrictions
Toprovideauniformbasisfor theperformanceevents,allvehiclesmustusethesameengine:astock four
stroke,aircooled,8kW(11horsepower),LombardiniLGA340engine.TheenginemustbeLombardiniLGA
340 engine. No other model or type of engine may be used. The required engine must remain completely
stockinallways,withthefollowingqualifications:
NOTE: Blueprinting(reworkinganenginetoamanufacturersexactspecifications)isconsideredmodification.
21.4.1ReplacementParts
OnlyoriginalequipmentLombardiniReplacementPartswillbepermitted.
21.4.2PistonRings
OnlystandardsizeoriginalLombardinipistonringsmaybeused.
21.4.3IntakePorts
Nocleaningorremovingofaluminumflashingfromintakeorexhaustportsisallowed.
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21.4.4Valves
(a)Valve Clearance Any valve clearance setting between tappet and valve stem intake and exhaust is
allowed,howeverchangingtheclearanceisnotrecommended.
(b)ValveLapping Valvesmaybelappedtoensurepropersealing.
21.4.5ShaftsandRods
Camshaft,crankshaft,connectingrodandflywheelmustnotbealteredormodified.
21.4.6SparkPlugs
OnlyRC12YCplugsarepermitted.Beforecarryinganyweldingactivity,itisrecommendedthatthesparkplug
cableisremovedandBatteryterminalcablesdisconnected.ThiswillpreventburningofwiringharnessandHT
Coil.
21.4.7FlywheelRotation
Noflywheelrotationtoadvanceorretardtimingispermissible.
21.4.8Carburetor
(a)CarburetorRejettingProhibited.Thisisafixedcarburetor,rejettingofthecarburetorisprohibited.
(b)IdleSpeed Lombardinirecommends1300+/ 100RPM.
(c)CarburetorFloat Carburetorfloatisnonadjustableandmaynotbereadjusted.
(d)CarburetorVenturi Modificationofcarburetorventuriisprohibited.
21.4.9AirCleaner
The air intake system should use a Filter from Enginetech, Pune. The filter should be located as close as
possibletotheengine.TheAirfilterinletdiametershouldbe22mm.Theairintakemayberelocated,butyou
mustuseLombardinipartstorelocatetheairfilter.Ateammayalsoaddadditionalprefilterstothetopofthe
airintake.Thesepartsmustbeincludedonthecostreport.Anychangesmadetotheairfilterwillhavetopass
Lombardini inspection. Tampering with the Engine Intake System including Air Filter & its Position is not
recommended;itmayleadtoreducedpowerandyieldinmisfiringduringvehicleretardation.Also,theintake
should comply with the instructions as provided by M/s Lombardini India Pvt Ltd for engine fitment. Any
damageonaccountoffailuretocomplywiththeinstructionswouldhavetobebornebytheteam.
21.4.10ExhaustSystem
(a)Muffler Anymufflerwhosebackpressuredoesnotexceed450mmofWaterColumnmaybeused.Other
exhaustsystemsareprohibited.Allexhaustgasmustpassthroughasinglemuffler. Multiplemufflersarenot
allowed.NOTE:Thisruleisunderreviewandmaybesubjecttochange.
(b)MufflerRelocation Ifthecardesignrequiresanexhaustsystemreconfigurationtokeepitfromimpinging
on part of the car, the rerouting must be done using tubing having an ID of 32 mm & OD of 35 mm. Any
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remote mounted exhaust system must be securely mounted so that it does not vibrate loose during the
competition.
(c)MufflerSupport Supportoftheexhaustpipeandmufflerarestronglyrecommended.
(d)ExhaustPipe Exhaustpipemaynotprotrudeinsideofexhaustportsoastoalterportconfiguration.
(e)ExhaustPipeLength Anyexhaustpipelengthisallowed,howeverpipelengthcannotbeadjustable.
(f)ExhaustPipeHoles&Tubes Noextraholesortubesareallowedintheexhaustpipe.
(g) Exhaust Pipe Durability Required The exhaust pipe and muffler must be completely intact and
operationalthroughouttheevent,andshallbegroundsforpenaltyordisqualificationifnotintactattheend
ofanyevent,includingenduranceevent.
21.4.11StarterRope
Recoilstarterropemaybeextendedtoaccommodatedriverstartingenginewhileseated.
21.4.12EngineGovernor
Eachengine isequippedwitha governor. Any attempt todefeat the enginegovernor soas to increase the
enginespeedwillresultinimmediatedisqualification.Beforetheperformanceevents,eachenginewillbeset
to a maximum speed of3600 rpm by means of the governor. Random inspection of the governor may be
conductedatanytime. GOVERNORSETTINGNOTTOEXCEED3600RPM!
21.4.13FuelSystem
Afueltankcapacitymaynotexceed6litres.Onlyonefueltankisallowedtobemountedinthevehicle.Fuel
pump supplied with the engine may be used (Refer section 35). In the interest of safety, it is strongly
recommendedthattheteamneedtodrainthefuelduringallrepairandservicingactivities.Thefueltankshall
besafelyconcealedfromtheexhaustandtheelectricalsystems,failingwhichthevehicleshallnotbeallowed
tocompeteinanydynamicevents.
21.4.14OnboardInstrumentation/DataAcquisition
Onboard instrumentation/data acquisition is allowed; the power for this instrumentation must be from
approvedbatteriesasper21.4.15.Ensurethattheaboveitems/systems,ifutilized,areincludedinyourteams
costreport.
21.4.15BatteryRequirements
Thebatteriescanonlyprovidepowertoaccessoriesonthevehicle(startermotor,brakelight,reverselight&
beeper,dataacquisitions,andotherinstrumentation).Itisexpresslyprohibitedtooperatethevehiclebyusing
power from an onboard battery. Multiple batteries may be used but all of them shall be used to power
accessoriesonly.Thebattery/smustbeabletoprovidepowertosafety itemsforthedurationoftheentire
event.Carswillbeblackflaggedifsafetyequipmentisnotfunctioning.Batteriesmustbemountedwithsound
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engineering practice. The mounting must prevent the battery from coming loose during a roll over. Prior
approval from the Technical Inspectors on any battery used is recommended to avoid conflicts during the
inspection at the competition. The battery must be enclosed from the exhaust and the fuel system. There
shouldnotbeanypositivecontactwiththeexhaustunitofthefuelsystem.Thebatterymustbesafelyplaced
andconcealed.Failingthis,thetechnicalinspectorsmaydebartheteamfromthedynamicevents.
NOTEfromLombardini: RecommendedBattery:12V,44Ah
21.4.16ElectronicControls
Electroniccontrolofsuspensionandtransmissionsystems isallowed.Allpowermustcomefromtheengine
itself.Thepowercancomefromanapprovedbattery(21.4.15)ifthebatteryisbeingchargedbytheonboard
alternatorontheLombardiniengine.
21.4.17StorageEnergyDevicesUsedforPropulsion
Hydraulicaccumulatorsaretheonlytypeofstoredenergydevicethatmaybe incorporated intoaBajaSAE
Indiavehicleforpropulsionpurposes.Ifemployed,hydraulicaccumulatorsmustbeatzeroenergyatthestart
ofeachevent.Hydraulicpowersystemsmustbeproperlyshieldedandmounted,anddocumentationofthe
shieldingmustbemadeavailableforreviewbytheTechnicalInspectors.NOTE:Hybridelectricpowersystems
arespecificallyprohibited.
21.5ComponentFailure
Intheeventofamajorcomponentfailureduringthecourseoftheevent,anymodificationsmustbeapproved
bytheTechnicalInspectorspriortothevehiclereturningtothecompetition.
21.6EngineInspection
Lombardiniengineserviceexpertswillbeonsiteduringthecompetitionandareempoweredto inspectany
engine at any time. The Lombardini staff on site is empowered to make final decisions regarding the
conditionandsetupofallengines.
21.7EngineUseRestriction
Lombardini generously provides engines to the teams for the exclusive purpose of use on their Baja SAE
Indiavehicle. If,foranyreason,ateamreceivesanengineandatalaterdatedecidesnottoparticipate,it
must,atitsownexpense,returntheenginetoSAEIndiaorLombardini.
NOTEfromLombardini:LOMBARDINIwillrepair/exchangedefectiveenginesfreeofcharge,however,ifitis
observed that the damages to the engine are caused due to teams negligence in handling/ installing/
runningtheengineasperthespecifieddirectionsgivenbyLombardiniorasspecifiedinthemanualsupplied
byLOMBARDINI, theteamsmaybe chargedfortherepairsorforprocuringanewengine inplaceof the
damagedengine.Nocomponents/sparesshallbeinstalledwithoutconsultingLOMBARDINIortheorganizer.
However,changesthatareexternaltotheengineunitandaresafefromthedesignandoperationalpointof
view are acceptable. These changes may include intermediate drive between the given engine and
transmission,etc.
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Queriesregardingtheengineandrelatedperipheralsmaybeaddressedtoengine.baja@bajasaeindia.org
22.Transmission
Teams are free to use any transmission such that maximum speed of the vehicle on a plain terrain is
recommendedtobenomorethan60km/hrintopgear.
23.ReverseLightandAlarm
Eachvehicleshouldbeequippedwithareverse light(white)andareversealarm.Thereverse lightshallbe
visibleataminimumdistanceof10metreswheninoperatingcondition.Itisnecessarytoensurethatthe
reverselightshalloperatewhenthereversegearisengaged.
24.TOWINGHITCHPOINT
Eachvehiclemusthavetowinghitchpointsatthefrontandrear,alongitslongitudinalcenterline.Wheninuse
hitch plates must be rigidly affixed to the vehicles main frame. Adjustable/repositionable hitch plates are
permitted.
NOTE:Towinghitchpointsarerequirementsforbothcompetitioneventsandvehiclerecovery.
24.1FrontHitchPoint
Thefronthitchpointmaybeeither:
(a)Atubularfrontbumperstrongenoughtolifttheweightofthecarwithnopermanentdeformationand
havingamaximumoutsidediameterof25.4mm(1in)towhichacleviscanbecentrallyattached,or(b)Ahitchplatecomplyingwiththerequirementsof24.3,whichisdesignedtofoldorpivot,intoaposition
whereitwillnotaffectanythingduringafrontendcollision.
EXAMPLESOFACCEPTABLEFRONTHITCHES
EXAMPLESOFFRONTHITCHESTHATARENOTACCEPTABLE
Cutawaysarenotallowed
DoesNot
Pivot
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24.2RearHitchPlate
Therearhitchpointmustbeaplatecomplyingwiththerequirementsof24.3.
24.3HitchPlateRequirementsMaximumandMinimum
TowingplateMaximumthickness 9.5mm(0.375in.)
HolediameterMinimum 25.4mm(1.0in.)
RadialclearanceMaximumfromhole 25.4mm(1.0in)
HoletotubeMinimumclearance19.0mm(.75in)
25.VehicleIdentification
25.1NumberAssignment
Assigned numbers may be found on the Baja SAE India website in the registered team list after final
registration.
It iseachteamsresponsibilitytoprovide itsvehiclenumbers. Thenumbersmustbeclearlyvisiblefrom
sides, both the front and rear of the vehicle. Additionally the team must see that the numbers remain
readablethroughoutthecompetition. Ifavehiclesnumbersareillegiblethenitmaynotbescored.
COMMENT:Schoolswhichareenteringmorethanonevehicleshouldconsiderpaintingtheminindividually
distinctivecolorstofacilitateinlapcounting.
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25.2VehicleNumberPrimaryCutout
Eachvehiclemustprominentlydisplayitsnumberaseitherasilhouetteorstencilformcutout.Thismustform
apyramidshapedplatesituatedatthetopofthevehiclewiththenumberstickerasstatedin25.3 &should
bevisiblewhenviewedfromall4sidesofthevehicle.Paintedonnumbersorstencils/decalsmountedflush
toabodypanelshallnotbeallowed.Thenumbersmustallowmudtoshedduringdynamicevents,sothat
carscanbeidentifiedaccurately.Thenumbermustbeablockstyleletterthat isclearandeasytoreadas
thesenumbersareessentialforlapcountingandvehicleidentification.Carswithnumbersthatarehardto
read,missing,damagedorobscuredmaynotbescoredandmaybeblackflagged.
25.2.1NumberLocation
Thesenumbersmustbeaffixedto:
Theuppersidesoftheframebetweentherearsupportandtherearrollhoop.Thenumbersmustbe inthe
verticalplaneofthesideofthecar.
TherearofthevehicleontheplanecontainingtheupperFABs(Fore/Aftbracing).
NOTE:Refertodiagram25formoreclarity.
25.2.2NumberSize
Thecutoutnumbersmustbeatleast203mm(8in)high.
COMMENT:Avoidhavingsharpedgesorpointsontheoutersidesofthecutoutnumbers.
DIAGRAM25:NUMBERANDLOGOPLACEMENT
Primar VehicleNumbersVehicleNumbersonbod
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25.3VehicleNumberBody
All vehicles must display their assigned number in block numerals on the front and both sides. These
numbersmustbeatleast20.3cm(8inches)high,haveaminimumlinewidthof2.54cm(1inch)andmust
stronglycontrastwiththebackgroundvehiclecolor.
25.4College Name
Allvehiclesmustdisplaytheircollegenameorinitials,inromancharacters,ifuniqueandgenerallyrecognized,
oneachsideincharactersatleast2.5cm(1inch)high.Teamsmayalsodisplaytheircollegenameinnon
romancharactersprovidedthattheromancharactersetishighestonthecar.
25.5SponsorLogos
25.5.1EventSponsorLogos
Sponsorslogosmustbedisplayedinaprominentspaceoneachsideofthevehicle(asperthediagram25).Thesewillbedistributedduringregistrationattheeventsite.
25.5.2SAEIndiaLogo
SAE India logoswouldbeprovided tothe teamsattheeventsiteonly.Thesearerequiredtobepastedon
bothsidesof thevehicle,atthecentreofthesidepanels,andabovetheheadof thedriver,atthe firewall
(referdiagram25).
25.5.3SponsorIdentification
Teamsmaydisplayadvertisingfromtheirvehiclessponsors,provideditisingoodtasteanddoesnotconflict
withthevehiclesnumber.
26.Transponders
26.1Transponders
Transponderswillbeusedaspartoftheprimarytimingsystemforallclosedloopdynamicevents.
It is each teams responsibility to ensure they have a functional, properly mounted and fully charged
transponderontheirvehicle.
Onetransponderwillbeprovidedtoeachteamfreeofcostatthetimeoftheevent(Thesewillhavetobe
returnedattheendoftheendurancerun).Howeveritistheresponsibilityoftheteamstodesignasecure
andsafemountingforthetransponders.
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26.2TransponderRequirement
AllvehiclesmustbeequippedwithatleastoneAMBTranX260Rechargeabletransponder.
See:www.ambit.com.
Thetimingsystemiscapableofrecordingtwotransponderidentificationspervehicle;
therefore,teamsmay,attheiroption,mountasecondtransponderasabackupincasethe
primaryisdamaged,knockedoffthecarorlosespower.
26.3TransponderMounting
Eachtransponderissuppliedwithamountingbracket(seephoto).Teamsareadvisedtoweldasmallplate
totheirframetoattachthisbracket. Thebracketcanbeattachedwithrivets,ziptiesorbolts.
Comment: Attaching the bracket with M4 pan OR flat head bolts with lock nuts OR wire is strongly
suggested.
Thetranspondermountingrequirementsare:
(1)Orientation The bracket must be mounted vertical to the frame in the orientation shown in the
photographandorientatedsothetranspondernumbercanbereadrightsideup.
(2) Location The transponder must be mounted on the drivers right side forward of the seat and
preferablywithinthe lowerhorizontalplaneofthe frontsuspension. Thetranspondermustbenomore
than61cm(24in)abovethetrack.
(3)UnobstructedTheremustbeanopen,unobstructedlinebetweentheantennaonthebottomofthe
transponderandtheground. (Donotmountthetransponderinsidethevehicleifsightlineisobstructed.)
Metal and carbon fiber may interrupt the transponder signal. The signal will normally transmit through
fiberglassandplastic. Ifthesignalwillbeobstructedbymetalorcarbonfiber,a10.2cm(4 in)diameter
openingcanbecutandthetranspondermountedflushwiththeopening.
(4)ProtectionMountthetransponderwhereitwillbeprotectedfromobstacles.
26.4TransponderBlackFlag
If,foranyreason,acarstransponderisnotbeingreceivedbythetimingsystemthenthecarwillbeblack
flaggedfortransponderrepair,relocationorreplacement.
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Section3RollCage,SystemsandDriversEquipmentRequirements
30.Introduction
The design and technical rules will be strictly enforced. It is the responsibility of each team to meet all
technicalrequirementsusingsoundengineeringprinciplesandconstructiondonemeetingproperfabrication
procedures. Failure to do so may mean disqualification from the competition; finaljudgment rest with the
TechnicalInspectors.Ifyouhaveanydoubtsaboutanytechnicalrequirement,presentyourquestionsbyemail
to technical@bajasaeindia.org. Technical Inspectors will do their best to answer these questions within two
weeks.Pleaseincludeyourname,school,contactinformationandtherulenumberinquestioninyouremail.
30.1RulesRequirementsandRestrictions
30.1.1TechnicalInspection
AllBajaSAEIndiavehiclesmustpassatechnicalinspectionbeforetheyarepermittedtocompete.Once
a vehicle has passed technical inspection it must remain in as approved condition throughout the
competition.Repairsmustbemadewithidenticalparts.
30.1.2RequiredModifications
All installations and construction are subject to the approval of the technical inspectors, who may
requiremodificationsattheirdiscretion.Allcompetitorsshouldbepreparedtonotethesemodifications
during technical inspections. Nomodifications in the designwouldbeallowed after theconclusion of
staticevents.Iffound,teamsshallbepenalizedwithaminimumdeductionof50pointssubjecttothe
modificationsdone.
30.1.3UnstableVehicles
Any vehicle exhibiting handling or other vehicle dynamics that are deemed unstable by the technical
inspectorswillnotbepermittedtoparticipateinthedynamicevents.
31.ROLLCAGE
31.1Objective
Thepurposeoftherollcageistoprovideaminimalthreedimensionalspacesurroundingthedriver. The
cagemustbedesignedandfabricatedtopreventanyfailureofthecagesintegrity. Thecagemustbelarge
enoughfor:
1.Thedrivershelmettobe15.24cm(6inches)awayfromastraightedgeappliedtoanytwopointsonthe
cockpitofthecar,excludingthedriversseatandthereardriversafetysupports.
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2.Thedriverstorso,knees,shoulders,elbows,hands,andarmsmusthaveaminimumof7.62cm(3in)of
clearancefromtheenvelopecreatedbythestructureofthecar.(Thisistestedbyapplyingastraightedged
betweenanytwopointsontheoutsideedgesofSIMandRHO,lesstherollcagepadding.)
31.2RollCageRequirements
31.2.1ElementsoftheRollCage
Theelementsoftherollcagethatmustmeetthematerialspecificationper31.5are:
RearRollHoop(RRH)Rule31.2.2
RollHoopOverheadMembers(RHO)Rule31.2.4
FrontBracingMembers(FBM)Rule31.2.7
LateralCrossMember(LC)Rules31.2.4and31.2.5
Additionalrequiredmembersmustbesteelandonlyhaveaminimumthicknessof.89mm(.035in)and
aminimumoutsidediameterof2.54cm(1.0in)andareasfollows:
LateralDiagonalBracing(LBD)
LowerFrameSide(LFS)
SideImpactMember(SIM)
Fore/AftBracing(FAB)
FrontLateralCrossMember(FLC)
Anytubethatisusedtomountthesafetybelts
Referencepoints:Seedrawingsinthissection.
NOTE: When minimal dimensions are given that is to the centerline of the members, and when a
clearance for the driver is given, it is definedby the outside edgesof theroll cage members less the
paddinginstalled.
*Allrollcagemembershavingabendradius>15.2cm(6inches)mayNOTbelongerthan71.1cm(28
inches)unsupported.
DEFINITION DRIVER Forthepurposesofthissection"driver"referstotheteam'slargestdriverand
the95percentilemaleproperlysuitedandwearingahelmet.
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31.2.2RearRollHoop(RRH)
The RRH is made up of a maximum of four sections: two LC at highest and lowest points and two
continuous,nobreakverticalmembers.Thismaybeonecontinuoushoop/tube.Thedriversseatmay
notintrude intotheplane(s)oftheRRH.Theupperjunctionsinstraighttubeconstructionshalldefine
pointsBRandBL. Ifbenttubeconstruction isused,pointsBRandBLwilloccurattheupperendofeach
bend(SeeRC1).TheRRHshallextendupwardvertically+/ 20degreesfrompointsAtopointsB.TheRRHmustalsobeaminimumof73.6cm(29in)wideat68.6cm(27in)abovethedriversseat(checked
byatemplate).
RC1
31.2.3RearRollHoopLateralDiagonalBracing(LDB)
LateralbracingfortheRearRollHoopshallbeginatapointalongtheverticalportionoftheRRHwithin
12.7cm(5inches)verticallyofpointBLorBRandextenddiagonallytoapointnofartherthan12.7cm(5
inches) abovepointAR orAL respectively. (SeeRC2) Theverticalangle between the RRH and the LDBmustbenolessthan20degrees.Lateralbracingmayconsistoftwoormoremembers.
RC2
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31.2.4RollHoopOverheadmembers(RHO)
RollHoopOverheadmembersshalljointheRRHwithin5.1cm(2inches)verticallyorlaterallyofpoints
BandextendgenerallyhorizontaltopointC.Thetubesmustbecontinuousandnobreakmembersfrom
pointBtopointCareallowed.TheRHOshallbelocatedabovethedriversseatbyaminimumof104.1
cm (41 inches).PointsCshouldbe located forwardof thedriversseatbyaminimumof30.5cm(12
inches)asdefinedinsection31.3(SeeRC3).PointsCRandCLshallbejoinedbyalateralcrossmember
(LC).
RC3
31.2.5LowerFrameSidemembers(LFS)
LowerframesidemembersshalljointheRRHLCandextendforwardtopointsforwardofthedrivers
heeltoafrontlateralcrossmember.(FLC)(SeeRC4) RC4
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31.2.6SideImpactmembers(SIM)
SideimpactmembersshalljointheRRHatpointsSandextendhorizontallytopointsSFforwardofthe
drivers toes. (See RC4) The SIM shall be between 20.3 cm (8 inches) and 35.6 cm (14 inches) (asmeasuredvertically)abovetheareaoftheseatincontactwiththedriver(SeeRC3).NOTE:ThedriversfeetmustbebehindtheplanecreatedbypointsAFR,LandSFR,L. Ifthetubebetween
SFR, L is below the drivers toes then an additional bar will be required above the drivers toes. (The
intentofthisistoprotectthedriversfeetfromatireintrusion.)
31.2.7FrontBracingmembers(FBM)
Front bracing members shalljoin the RHO, the SIM and the LFS (See RC5). The upper front bracingmembers(FBMUP)shouldextenddownwardandforwardandjoinpointContheRHOtotheSIMator
behindpointsSF.TheFBMmembersmustbecontinuousandnobreakmembersfrompointCtothe
SIMareallowed.TheanglebetweentheFBMUPandtheverticalshouldbelessthan45degrees.
RC5
31.2.8RollHoopBracing(FAB)
Therollhoopcanbebracedinthefrontand/orrear. Thehoopmustbebracedonbothrightandleft
sides. Fromasideview,thebracingmustbetriangulated,withthemaximumlengthofanymembernot
toexceed101.6cm(40inches)betweenattachmentpoints.Theanglesofthetriangulationmustbeno
lessthan20degrees. Abenttubecannotexceed81.3cm(32inches)betweenattachmentpoints.
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31.2.8.1FrontBracing
IffrontbracingisuseditmustconnectFBMup,LFSandtheSIM. Frontbracingmustbeattached
ascloseaspossibletothetopoftherollcage(pointC).
31.2.8.2RearBracing
Ifrearbracingisuseditmustbeattachedascloseaspossibletothetopoftherollhoopalong
theouterperimeter. ThebracingmustbetriangulatedandconnectbacktotheRRHbelowthe
SIM.
31.2.9RHO/FBMGusseting
IftheRHOandFBMarenotfabricatedfromacontinuoustube,agussetisrequiredatpointC.Gussets
shallbemadeofsteelplate,betriangularfromasideview,andhaveaminimumthicknessof0.065.
Thegussetsshallbeweldedtothesidesofthetubesandnotdirectlyintheplaneofthetubesmaking
upeachjoint(SeeRC6).Thelengthofthegussetmustbeatleast3timesthetubediameter.
RC6
TheexampleontheleftshowsadesignwheregussetingisrequiredatpointC;theexampleontheright
shows
a
frame
where
gusseting
would
not
be
required
at
point
C.
31.2.10ButtJoints
Allbuttjointswithinanyoftheelementsontherollcagelistedinsection31.2.1(excludingtherequired
nobreakmembersdescribed in31.2.2,31.2.4and31.2.7)mustbereinforcedwithaweldedsleeve.A
buttjointisdefinedasajointwheretwotubescometogethergenerallyalongthesamelineandarenot
supportedbyathirdtubeatthenode.Thesleevemustbedesignedtotightlyfitonthe insideonthe
jointbeingreinforced(i.e.externalsleevesarenotallowed),mustextendintoeachsideofthesleeved
joint,alengthofatleasttwotimesthediameterofthetubesbeingreinforced,andbemadefromsteel
atleastasthickasthetubesbeingreinforced.Inadditiontomeetingbasicgeometryrequirements,the
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sleeve must be designed and fabricated to both reinforce the joint and to distribute the stress
concentrationsoftheheataffectedzone.
31.2.11WeldConfirmationChecks
Teamsmustconductweldconfirmationtesting foreachwelderthatweldstheirvehiclerollcage.The
teammustdemonstrateitsabilitytoproduceweldedjointsofaknownqualitywithmaterials,toolsand
procedures similar to those being used in the fabrication of the chassis. The team must conduct
destructivetestingusingthefollowingrequirements:
Thefollowingdefinitionswillapplytotheentiretyofrule31.2.11:
AsBuiltVehicle:thevehiclepresentedattechnicalinspection
RollCageElements:elementsoftherollcageasdiscussedinrule31.2.1
RollCageWelds: anyweldjoiningtwoor moreroll cageelements oroneormorerollcage
elementsandoneormoregussetsasdiscussedinrule31.2.9
RollCageMaterial:tubingofthesamegeometryandalloyastherollcageelementsoftheas
builtvehicle
RollCageWelder:anyperson thatperformsweldingof therollcageweldsoftheasbuiltvehicle
Each roll cage welder must demonstrate sufficient welding skill and craftsmanship with the tools,
processes and roll cage material. In addition to visual inspection of the asbuilt vehicle, the national
technicalinspectorswillcollectandinspectweldingsamplesduringthetechnicalinspectionprocessto
determine dynamic and endurance event competition eligibility. Teams unable to submit welding
samples of adequate quality, as defined below, shall not be eligible to compete in any dynamic or
enduranceevent.
NOTE:Onlystudentsaretoperformweldingontheasbuiltvehicle,androllcageweldersmaybeasked
todemonstratetheirweldingskillsduringtechnicalinspection.
Eachteammustsubmittwo(2)samplesforeachrollcagewelder,bothofwhichareconstructedof
rollcagematerialwhichhavebeenweldedwiththesametoolsandprocessesasthoseoftheasbuilt
vehicleandwhichhavealsobeensubjecttothefollowingdestructivetestingandinspection:
Sample1DestructiveTesting:
A structure made up of roll cage tubing welded at a 90 degree angle, the length of each tube to be
determinedbytheteam.Thisjointshouldbesubjecttodestructivetestingcausingthejoint
tofailtowhichindicatessuperiorweldstrengthwithrespecttothebasematerial.(Thetestingmethod
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islefttotheteamsdiscretion.Forexample,teamscandopulltestinginalab,orapplyamomenttoone
sideofthejointwhilefixingtheothersideofthejoint.)
Sample2DestructiveInspection:
Astructuremadeupofrollcagematerialthathastwotubesattachedata30degreeanglewithalength
ofat least15cmfromthecenteroftheweldjoint.Thesampleshouldbesectionedalong
thelengthoftubetorevealadequateanduniformweldpenetration.
Finaljudgmentofweldstrengthwithrespecttothebasematerialas itdescribed insample1andthe
adequacy and uniformity of weld penetration as described in sample 2 shall rest with the national
technicalinspectors.
Welding samples constructedofmaterialother than the roll cagematerialand /orweldedwitha
processotherthanthatoftherollcageweldsoftheasbuiltvehicleshallnotbeconsideredsufficient
demonstrationofweldingskillandcraftsmanshipwiththetools,processesandrollcagematerial.
Note: Frames thatwere constructed in aprevious yearwillneed tohave samplesweldedby that
welderorremovetwosectionsofthecurrentframeandperformthetestsonthesecomponents.
31.2.12FinalJudgment
TherulesareconsideredaminimumbutthefinaljudgmentwillrestwiththeTechnical Inspectors. If
during the event, any frame shows signs of yield and/or failure the car will be removed from
competitionuntilthetechnicalinspectorsconfirmthattheframecomplieswiththerulesagain.
COMMENT:Notethat inallcases,especiallybenttubeconstruction,technical inspectorsmayrequire
additional bracing if they feel the roll cage does not offer adequate protection. Any tubes showing
cracksanddeformationdonotcomplywiththerules.
31.3HeadRestraint
Aheadrestraintmustbeprovidedonthecartolimitrearwardmotionoftheheadincaseofanaccident.
Therestraintmusthaveaminimumareaof232sq.cm (36sq inches),andbepaddedwithaclosedcell
foam that has a density of 50100 kg/m^3. The restraint must be a minimum thickness of 3.8 cm (1.5
inches),andbelocatednomorethan2.5cm(1inch)awayfromthehelmetintheuncompressedstate.The
head restraint must be securely mounted to the vehicle. The head restraint must meet the above
requirementsforalldrivers.
NOTE:Iftheheadrestraintisalreadyapartoftheseat,thennoneedtoincludeaseparateone.
Fi ure1
Fi ure2 Figure3
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31.4DriverHeadClearance
Fordriverheadclearance,therollcagemustextendaminimumof104.1cm(41inches)abovetheseating
surface to the bottom of the upper roll cage tubes measured vertically using the template in RC 3. The
template radiused bottom should be placed in thejoint of the seat base and the seat backrest and
positioned vertically. The template tee top describes the projection of the required clearance height
forward and rearward. While the template fixes the clearance height forward, the clearance height
rearward must be extended in each design over the helmet top of a seated and secured driver. Taller
drivers may be accommodated by lengthening the template vertical member and raising the entire
clearanceheightenvelopeabovethe104.1cm(41inches)minimum.
31.4.1HeadClearanceMinimum
Inallcases,aminimumof15.2cm (6 inches)
vertical clearancemustbeprovided from the
helmet topofthe teams tallestdriverto the
bottomoftherollcagetoptubesormembers.
31.5RollCage&BracingMaterials
The material used for the entire required roll
cage members specified in 31.2.1 must, at
minimum,be:
(A)Circularsteeltubingwithanoutsidediameterof2.5cm(1inch)andawallthicknessof3.05mm(.120
inch)andacarboncontentofatleast0.18%.
OR
(B)Steelmemberswithatleastequalbendingstiffnessandbendingstrengthto1018steelhavingacircular
cross section with a 2.54 cm (1 inch) outer diameter and a wall thickness of 3.05 mm (.120 inch). All
calculationsshowingtheequivalencemustbeinSIunits.
NOTE:Theuseofalloysteeldoesnotallowthewallthicknesstobethinnerthan1.57mm(.062inch).
Thebendingstiffnessandbendingstrengthhavetobecalculatedaboutanaxisthatgivesthelowestvalue.
BendingstiffnessisproportionalbytheEIproduct.BendingstrengthisgivenbythevalueofSyI/c,(for1018
steelthevaluefor;Sy=365Mpa).
E=Themodulusofelasticity(205GPaforallsteels)
I=Thesecondmomentofareaforthecrosssectionabouttheaxisgivingthelowestvalue
Sy=Theyieldstrengthofmaterialinunitsofforceperunitarea
c=Thedistancefromtheneutralaxistotheextremefiber
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31.5.1RollCageSpecificationSheetRequired
All teams must bring a copy of the Baja SAE India Roll Cage Specification Sheet (See Section 8 Forms &
Deadlines)totheTechnicalInspectorsduringtechnicalinspection.Theseformsmustbecompletedforeach
competition.CompleterollcagespecificationsmustbesuppliedwiththeRollCageSpecificationSheet. Teams
thatdonotsubmitaRollCageSpecificationSheetwillnotbeallowedtocompete.
31.5.1.1MaterialsDocumentation
Teamsarerequired tobringwith them toTechnical Inspectiondocumentation (invoices,bills,
etc.)ofthematerialsusedfortheconstructionoftherollcageandbracing.
31.6RollCagePadding
Any portion of the roll cage, roll cage bracing, side impact member or frame (excluding rear roll hoop)
betweentheweldjointswhichwouldbecontactedbythedriver,mustbecoveredbyaresilientfoammaterial
suchasPolyethylene(pipeinsulation)withaminimumthicknessof1.2cm(.5inch).
31.7SharpEdgesonRollCageProhibited
All sharp edges which might endanger the driver, crew, officials and safety staff must be eliminated by
shieldingand/orpadding.Thisincludesbrackets,gussets,sheetstock,fastenerends,clamps,ziptiesorother
featuresaccessibleduringservicing,judgingorcompetitionimpactorrollover.
31.8BoltedRollCages
BoltedRollcagesareacceptableonlyifthefollowingrequirementsaremet:
(A)Flangesortabsmustbetwice(2X)thethicknessofthetubestructures,madeofthesamematerialtype.
Theymustbeproperlyweldedtoeachtubingparttobejoined.
(B)Flangemountsmustbetwice(2X)thediameteroftheattachedtubing,flushmated,andwithnogap
betweenthefacesgreaterthan.07mm(.003)inches.
(C)Tabmountsmustbedual,parallelandoneachsideofthetubingtowhichtheyarewelded,havinga
weldedlengthofatleasttwice(2X)thediameteroftheadjoined.Tubingheldbyboltsmustbereinforced
suchthattheareathroughwhichtheboltpassescannotbecompressedfromtighteningorimpact.
31.9DriverSeat
Theuseofadriverseatismandatory;cushioningorpaddingattachedtotheframeand/orfirewallwillnot
be accepted as a seat. The seat shall be fastened to the frame and shall support the entire body of the
driver(fulltorsoandhead).Theloadshallnotbetransferredtothefirewalloranyothermemberexcept
thosesupportingtheseat.Aclearanceof3betweenthefirewall,SideImpactMembersandtheseatmust
bemaintained.Theuseofcommerciallyavailablerallyseatsishighlyrecommended.
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32.COCKPIT
32.1DesignObjective
Thecockpitmustbedesignedto(1)protectthedriverand(2)permiteasydriverexitinanemergency.
32.2DriverExitTime
Alldriversmustbeabletoexitoneithersideofthevehiclewithinfive(5)seconds.Exittimebeginswiththe
driverinthefullyseatedposition,handsindrivingpositionontheconnectedsteeringwheel,andwearing
therequireddriverequipment.Exittimewillstopwhenthedriverhasbothfeetontheground. Drivers
exittimemustbedemonstratedbyateamdriver,ordriversselectedbythetechnicalinspectors.
32.3Firewall
A firewall between thecockpit and theengineand fuel tank compartment is mandatory. It mustcover the
areabetweenthelowerandupperlateralcrossmember.Thisfirewallmustbemetal,atleast.508mm(.020
inch)thick,andmustcompletelyseparatetheenginecompartmentandfueltankfromthecockpit.Multiple
panelsmaybeusedtoformthefirewallbutmusthavenogapsbetweenthejoints.Cutoutsinthefirewallare
allowed,buttheyneedtohavegrommetsorbootsthatpreventlargeamountsoffuelfromgettingintothe
cockpit.
32.3.1FrontorMidengineCars
If the engine is not placed in the rear of the car, then a firewall is not required to cover the area
between the lower and up