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Tie Rod Tab (UBC Baja SAE)

A compact steering mount designed for reliable fit-up, stronger load transfer, and practical fabrication in a real race-team workflow.

From Prototype to Chassis Fitment

Detailed project page

Tie rod tab installed on upright with rods connected.

Problem Definition

The steering linkage needed a mounting tab that fit tight packaging, survived load cycles, and stayed fabrication-friendly for the Baja chassis process.

Problem Solution

I iterated tab geometry through CAD and prototype checks, then verified mounting and integration on the upright and car to keep the final part practical, repeatable, and structurally sensible.

Design and Validation

Fitment test cycle on real hardware (turn on sound!)
3D printed tie rod tab front-side prototype.
3D-printed front prototype
3D printed tie rod tab rear-side prototype.
3D-printed rear prototype
Front mounting view of tie rod tab on upright.
Front mounting view
Rear mounting view of tie rod tab on upright.
Rear mounting view
Tie rod tab mounted on upright installed on the car.
Integrated on-car installation
Tie rod tab mounted on upright without full vehicle context.
Bench-mounted upright fit check
Overseeing machining process for tie rod tab parts.
Manufacturing oversight during machining
Tie rod tab assembly and suspension area detail.
Final assembly detail view

Load-Path and Safety Check

The design process balanced packaging constraints with manufacturability and load confidence.

Prototype prints, bench fit checks, and installed-vehicle verification were used to converge on a mount that could move from concept to team-ready hardware.

Factor of safety and stress visualization for tie rod tab concept.
Early stress and factor-of-safety reference used to guide iteration.

Design Review Highlights

Targets

  • Minimum factor of safety target: 1.2
  • Validated minimum observed: 1.657 @ 2250 lbf
  • Weight optimization to reduce unsprung mass

Load Case

  • Design load: car + driver at 3g impact
  • Equivalent load basis: 10 kN (2250 lbf)
  • Load path concentrated through tie rod into tab

Build Constraints

  • In-house CNC manufacturability in tight packaging
  • Geometry tuned for upright assembly clearance
  • Complexity tradeoff balanced against robustness

Part Specs

  • Material: Al 6061-T6
  • Part mass: 0.28 lb
  • No easy trackside replacement, so safety margin prioritized

Open full design review deck (.pptx)

Tags Baja SAE Steering hardware Mount design
Baja SAE Steering hardware Mount design Prototype validation Fabrication-ready CAD
Skills Mechanical design CAD iteration Fit-up validation
Mechanical design CAD iteration Fit-up validation Design for manufacturing Engineering communication