4WD Drivetrain Design

Designing and building a chain-driven 4WD system

For my senior project at Union College I designed a chain-driven 4WD system for the 2022-23 SAE Baja car. After suffering a catastrophic mechanical failure in the shaft-driven drivetrain at the 2022 collegiate competition, the car was in need of a more robust and reliable system. The drivetrain system I designed featured a custom designed 2:1 reduction gearbox, front and rear jack-shafts, and an adjustable chain tensioning mechanism for both front and rear chains. In addition to the chain system, I also designed sheet metal chain guarding for the footwell and cabin to protect the driver. This system proved to be both robust and reliable leading to the most successful Union Baja performance at competition to date, and remained in use for multiple years.

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Braking System Design