2011 Table of Contents

Section:

Pages:

1. Cost Summary4
2. Bill of Materials..5 - 7
3. Brake System- BR...10 - 36
4. Engine & Drivetrain- EN....37 - 83
5. Frame & Body- FR..84 - 102
6. Electrical- EL...103 - 120
7. Misc, Finish & Assembly- MS....121 - 126
8. Steering System- ST....127 - 145
9. Suspension System- SU...146 - 182
10.Wheels, Wheel Bearings & Tires- WT....183 - 195
11.Complete Vehicle Pictures...196 200

2011 Cost Summary Basics

University of Akron
Car # 73

FOR:

Area Totals

Materials

Processes

$
$
$
$
$
$
$
$

171.30
506.22
499.32
312.30
62.51
53.52
586.93
762.32

Fasteners

$
$
$
$
$
$
$
$

7.42
37.49
50.66
0.62
9.50
44.88
14.72

Tooling

Total

BR

Brake System

EN
FR
EL
MS
ST
SU
WT

Engine & Drivetrain

Frame & Body
Instruments & Wiring
Miscellaneous, Fit & Finish
Steering System
Suspension & Shocks
Wheels & Tires

$ 1,066.18
$ 2,347.20
$ 470.83
$ 2,178.52
$ 121.24
$ 107.30
$ 1,835.47
$ 997.30

$
$
$
$
$ 99.93 $
$
$
$
$
$ 0.02 $
$ 64.01 $
$ 20.00 $

1,244.90
2,890.91
1,120.73
2,490.81
184.37
170.34
2,531.29
1,794.34

Total Vehicle

$ 9,124.03 $ 2,954.42 $ 165.29 $ 183.96 $

12,427.69

Composition for total vehicle:

Area Totals

Brake System
Engine & Drivetrain

$1,794.34 , 15% $1,244.90 , 10%

Frame & Body

$2,890.91 , 23%

$2,531.29 , 20%

Instruments & Wiring

Miscellaneous, Fit & Finish

$170.34 , 1%
$184.37 , 2%

$2,490.81 , 20%

$1,120.73 , 9%

Steering System
Suspension & Shocks

Wheels & Tires

University
Competition Code
Year
Car #

Line
Num.
Area of Commodity
1
Brake System
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Brake System
19 Engine & Drivetrain
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
Engine & Drivetrain
56 Frame & Body
57
58
59
60

University of Akron
FSAEM
2011
73

Asm #
A1001

A1002

A1003

A2001

A2002

A2003

A2004

A2005

A2006

A2007

A3001

A3002

Asm
Front Rotor Assembly

Rear Rotor Assembly

Brake Line Assembly

Engine Assembly

Exhaust Assembly

Air Intake Assembly

Fuel Assembly

Cooling Assembly

Differential Assembly

Drivetrain Assembly

Pedals & Controls Assembly

Tube Space Frame Assembly

Total Vehicle Cost

Part #
P1001
P1002
P1003
P1004
P1005
P1006
P1007
P1008
P1009
P1010
P1011
P1012
P1013
P1014
P1015
P2001
P2002
P2003
P2004
P2005
P2006
P2007
P2008
P2009
P2010
P2011
P2012
P2013
P2014
P2015
P2016
P2017
P2018
P2019
P2020
P2021
P2022
P2023
P2024
P2025
P2026
P2027
P2028
P2029
P2030
P3001
P3002
P3003
-

Component
Brake Disks
Brake Bobbins
Brake Calipers
Brake Pads
Brake Hats
Brake Disks
Brake Bobbins
Brake Calipers
Brake Pads
Brake Hats
Brake Line
Fluid Reservoir
Master Cylinder
Fittings
Balance Bar
Area Total
Engine
Oil Pan
Exhaust Flange
Headers
Muffler
Collector
Air Filter
Thermal Gasket
Throttle Body
Aluminum Plenum
Fuel Injector, Gasoline
Fuel Pump
Fuel Tank
Fuel Pressure Regulator, GAS
Fuel Filter
Fuel Lines
Fuel Check Valve
Fuel Rail
Radiator
Coolant Lines
Housing
Differential Internals
Left Bearing Carrier
Right Bearing Carrier
Front Sprocket
Rear Sprocket
Chain Guard
Axle
Constant Velocity Joints
Chain
Area Total
Brake Pedal
Gas Pedal
Clutch Lever

Description
Complete Front Brake Asm
Cast Iron Brake Disk
Aluminum Bobbin
Wilwood, PS-1
Iron/Steel Pad
Aluminum Hat
Complete Rear Brake Asm
Cast Iron Brake Disk
Aluminum Bobbin
Wilwood, PS-1
Iron/Steel Pad
Aluminum Hat
Complete Brake Line Asm
Steel Braided Lines
Hydraulic Fluid Reservoir
Master Cylinder, Tilton, Model 77
Brake Line Fittings
Balance Bar, Tilton, 72-281

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

Unit Cost
2.50
5.31
3.47
49.04
2.72
8.62
3.86
3.47
49.04
2.72
8.62
3.25
18.34
16.67
198.62
138.32
314.63

Quantity
1
2
12
2
4
2
1
2
12
2
4
2
1
1
1
2
1
1

Engine & Oil Pan

Yamaha R6
Aluminum Oil Pan
Student Built Exhaust
308 Stainless Exhaust Flange
Custom Fit Headers
Student Built Muffler
Student Built Collector
Complete Air Intake Assembly
SLA Intake
Student built Gasket
Aluminum Throttle Body
Purchased Air Filter
Complete Fuel Assembly
Purchased Fuel Injector
Student Purchased Fuel Pump
Aluminum Gas Tank
Student Purchased Fuel Regulator
Fuel Filter
Complete Line Assembly
Student Purchased Check Valve
Student Made Fuel Rail
Radiator, Coolant Lines
Aluminum Radiator/Overflow/Fan
Hoses and Plumbing
Complete Differential Setup
Student Made
Purchased Internals
Student Made Carrier
Student Made Carrier
Complete Drivetrain Assembly
13 Tooth Sprocket, Front
Student Built
Student Built
Student Bought
Purchased CV Joints
Chain

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

3.75
1,644.45
55.38
0.52
4.80
38.49
22.84
21.34
5.79
26.83
1.89
45.03
15.49
10.52
37.53
82.91
16.33
8.00
67.42
8.00
18.27
12.02
67.22
13.45
7.01
110.90
54.77
54.15
5.57
2.99
20.14
6.03
12.32
190.00
25.00

1
1
1
1
4
4
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1

All Brakes & Controls

Aluminum Brake Pedal
Aluminum Gas Pedal
Aluminum Lever
All Body Parts Included

$
$
$
$
$

4.89
25.43
14.73
8.30
-

1
1
1
1
1

Material Cost
$
$
1.05
$
0.04
$
46.00
$
2.46
$
1.93
$
$
1.05
$
0.04
$
46.00
$
2.46
$
1.93
$
0.75
$
16.47
$
16.54
$
197.50
$
108.32
$
312.50
$
1,066.18

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

1,607.00
41.33
0.88
4.79
9.37
2.42
0.40
2.51
0.29
40.30
14.12
10.00
35.00
5.25
15.00
8.00
55.42
8.00
0.48
3.00
64.78
9.85
110.00
13.02
13.02
0.21
2.40
2.05
3.15
190.00
25.00
2,347.20
5.96
3.81
2.10
-

Process Cost
2.50
4.26
3.29
2.80
0.26
6.29
2.81
3.29
2.80
0.26
6.29
2.50
1.35
0.13
0.63
30.00
2.13
171.30
3.75
28.63
14.06
0.52
1.52
33.70
13.47
18.92
4.99
24.32
1.60
4.35
0.63
0.52
0.13
77.50
1.33
12.00
17.79
9.02
1.30
0.46
6.05
40.85
41.13
5.57
2.78
11.50
2.68
8.97
506.22
4.89
17.83
9.36
5.30
-

Fastener Cost
$
$
$
0.14
$
0.24
$
$
0.40
$
$
$
0.14
$
0.24
$
$
0.40
$
$
0.52
$
$
0.49
$
$
$
7.42

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

8.82
2.40
0.40
0.38
0.74
2.40
0.16
1.14
3.15
0.96
0.90
0.90
6.24
1.30
0.20
37.49
1.64
1.56
0.90
-

Tooling Cost
$
-

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

Total Cost
2.50
10.62
41.61
98.08
10.87
17.24
7.72
41.61
98.08
10.87
17.24
3.25
18.34
16.67
397.24
138.32
314.63
1,244.90
3.75
1,644.45
55.38
0.52
19.22
153.94
22.84
21.34
5.79
26.83
1.89
45.03
15.49
42.08
37.53
82.91
16.33
8.00
67.42
8.00
18.27
12.02
67.22
13.45
7.01
110.90
54.77
54.15
5.57
2.99
20.14
6.03
24.64
190.00
25.00
2,890.91
4.89
25.43
14.73
8.30
-

12,427.69

Details Page
Number
10
11
13
15
16
17
19
20
22
24
25
26
28
29
30
32
34
35
37
38
39
40
41
42
43
45
46
47
49
51
52
53
54
55
56
58
59
60
61
62
63
64
66
67
68
69
70
72
74
75
76
78
80
82
83
84
85
87
89
90

Line
Num.
61
62
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131

Area of Commodity

Asm #

A3003

A3004
Frame & Body
Electrical

Instruments & Wiring

Miscellaneous, Fit & Finish

Miscellaneous, Fit & Finish

Steering System

A4001

Body Assembly

Linkage Assembly

Engine Electronics Assembly

A4002

Main Wire Harness Assembly

A4003

Kill Switch Assembly

A4004

Dashboard Assembly

A4005

Brake Light Assembly

A4006

Shifting Solenoids Assembly

A4007

Indicator Light Assembly

A4008

Battery Assembly

A4009

Starter Switch Assembly

A5001

A6001

Cockpit Safety & Seating Assembly

Steering Rack Assembly

A6002

Steering Column Assembly

A6003

Steering Wheel Assembly

A6004

Steering System
Suspension

Asm

A7001

A7002

A7003

Tie Rod Assembly

Dampener Assembly

Push Pull Rod Assembly

Front A-Arm Assembly

A7004

Rear A-Arm Assembly

A7005

Front Bell Crank Assembly

Part #
P3004
P3005
P3006
P3007
P3008
P3009
P3010
P3011
P4001
P4002
P4003
P4004
P4005
P4006
P4007
P4008
P4009
P5001
P5002
P5003
P5004
P6001
P6002
P6003
P6004
P6005
P6006
P6007
P6008
P6009
P6010
P6011
P7001
P7002
P7003
P7004
P7005
P7006
P7007
P7008
P7009
-

Component
Tube Frame
Tab Points
Structural Reinforcements
Right Side Panel
Left Side Panel
Nose Cone
Hood
Clutch Linkage
Area Total
Engine Harness
Main Harness
Kill Switch
Dashboard
Brake Light
Shifting Solenoids
Indicator Light
Battery
Starter Switch
Area Total
Seat
Headrest
Paint
Firewall
Area Total
Pinion Gear
Rack Gear
Steering Rack
Steering Rack Housing
Column Joints
Column Joints
Steering Wheel
Quick Release
Rod Tube
Rod Inserts
Rod Ends
Area Total
Dampener
Coil Springs
Rod Tube
Rod Inserts
Rod Ends
Lower A-Arm
Upper A-Arm
Lower A-Arm
Upper A-Arm

Description
Complete Tube Space Frame
All Tabs and Stock
All Body Parts Attached
Floor & Side Panels
Right Side Panel
Left Side Panel
Nose Cone
Hood
All Linkages
Clutch Linkage

Unit Cost
$
442.47
$
94.58
$
$
162.83
$
93.29
$
93.29
$
93.40
$
56.12
$
$
31.40

Quantity
1
1
1
1
1
1
1
1
1
1

Wire Harness & ECU

Student Built
Main Wire Harness
Student Built
Kill Switch
Student Built
Dashboard
Student Built
Brake Light
Student Built
Shifting Solenoids
Student Built
Indicator Light
Student Built
Battery
Battery
Starter Switch
Starter Switch

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

2,000.18
223.50
83.06
34.34
81.28
7.50
1.00
58.96
1.00

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Cockpit Safety & Seating

Foam Bead Seat
Hand Made Head Rest
Black Spray Paint
2 Part Firewall

$
$
$
$
$

49.33
22.40
44.78
13.90
53.96

1
1
1
1
1

Complete Steering Rack

Rack Gear
Steering Rack Gear
Aluminum Rack
Carbon Rack Housing
Steering Column & Shaft
U-Joint for Column
Steel Tube Column
Steering Wheel
Carbon Fiber Steering Wheel
Aluminum Quick Release
Steel Tie Rod Assembly
Steel Tubing
Student Built
Student Bought

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

6.38
7.06
11.02
26.61
42.39
6.49
26.68
8.17
6.72
0.93
7.50
17.60

1
1
1
1
1
1
1
1
1
1
1
1
4
1
1

Damper Setup
Penske Damper
Steel Coil Spring
Push/Pull Rod Assembly Front/Rear
Steel Tubing
Student Built
Student Bought
Complete Front A-Arm
Steel Lower A-Arm
Steel Upper A-Arm
Complete Rear A-Arms
Steel Lower A-Arm
Steel Upper A-Arm
Front Aluminum Bell Crank

$
$
$
$
$
$
$
$
$
$
$
$
$
$

12.00
338.46
25.24
5.52
0.36
12.83
17.60
25.79
25.02
29.07
28.84
-

1
4
4
1
4
1
1
1
2
2
1
2
2
1

Material Cost
Process Cost
Fastener Cost
$
60.93 $
294.43 $
$
1.85 $
87.40 $
$
$
$
$
118.33 $
44.50 $
$
63.20 $
10.90 $
16.80
$
63.20 $
10.90 $
16.80
$
85.05 $
6.07 $
0.96
$
36.40 $
6.34 $
12.00
$
$
$
$
30.00 $
1.40 $
$
470.83 $
499.32 $
50.66
$
$
$
$
1,885.50 $
114.68 $
$
$
$
$
129.50 $
94.00 $
$
$
$
$
17.50 $
65.56 $
$
$
$
$
13.06 $
21.28 $
$
$
$
$
64.50 $
16.78 $
$
$
$
$
7.50 $
$
$
$
$
$
1.00 $
$
$
$
$
$
58.96 $
$
$
$
$
$
1.00 $
$
$
2,178.52 $
312.30 $
$
45.00 $
3.71 $
0.62
$
18.00 $
4.40 $
$
8.74 $
36.04 $
$
13.90 $
$
$
35.60 $
18.36 $
$
121.24 $
62.51 $
0.62
$
$
$
$
0.62 $
5.16 $
0.60
$
1.30 $
5.16 $
0.60
$
2.51 $
8.51 $
$
22.21 $
4.40 $
$
$
$
$
40.00 $
1.00 $
1.39
$
0.44 $
6.05 $
$
$
$
$
17.09 $
9.57 $
$
1.38 $
6.60 $
0.19
$
$
$
6.72
$
0.93 $
$
$
0.43 $
7.07 $
$
17.60 $
$
$
107.30 $
53.52 $
9.50
$
$
12.00 $
$
337.50 $
$
0.96
$
25.00 $
0.24 $
$
$
$
5.52
$
0.36 $
$
$
0.43 $
7.07 $
$
17.60 $
$
$
$
$
$
11.70 $
5.83 $
1.59
$
11.10 $
5.72 $
1.53
$
$
$
$
11.99 $
8.88 $
1.53
$
11.76 $
8.88 $
1.53
$
$
$
-

Tooling Cost
Total Cost
$
87.11 $
442.47
$
5.33 $
94.58
$
$
$
$
162.83
$
2.39 $
93.29
$
2.39 $
93.29
$
1.32 $
93.40
$
1.38 $
56.12
$
$
$
$
31.40
$
99.93 $
1,120.73
$
$
$
$
2,000.18
$
$
$
$
223.50
$
$
$
$
83.06
$
$
$
$
34.34
$
$
$
$
81.28
$
$
$
$
7.50
$
$
$
$
1.00
$
$
$
$
58.96
$
$
$
$
1.00
$
$
2,490.81
$
$
49.33
$
$
22.40
$
$
44.78
$
$
13.90
$
$
53.96
$
$
184.37
$
$
$
$
6.38
$
$
7.06
$
$
11.02
$
$
26.61
$
$
$
$
42.39
$
$
6.49
$
$
$
0.02 $
26.68
$
$
8.17
$
$
6.72
$
$
3.72
$
$
7.50
$
17.60
$
0.02 $
170.34
$
$
12.00
$
$
1,353.84
$
$
100.96
$
$
5.52
$
$
1.44
$
5.33 $
12.83
$
$
17.60
$
$
$
6.67 $
51.58
$
6.67 $
50.04
$
$
$
6.67 $
58.14
$
6.67 $
57.68
$
$
-

Details Page
Number
91
93
94
95
96
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
124
125
126
127
128
130
131
132
134
135
136
137
138
140
141
142
143
144
146
147
148
149
150
151
152
153
154
155
156
157
158
159

Line
Num.
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
159

Area of Commodity

Asm #
A7006

Rear Bell Crank Assembly

A7007

Front Upright Assembly

A7008

Rear Upright Assembly

A7009

Front Roll Bar Assembly

A7010

Suspension & Shocks

Wheels & Tires

A8001

A8002

A8003

Wheels & Tires

Vehicle Total

Asm

Rear Roll Bar Assembly

Wheel Assembly

Front & Rear Hub Assembly

Wheel Bearing Assembly

Part #
P7010
P7011
P7012
P7013
P7014
P7015
P7016
P7017
P7018
P7019
P7020
P7021
P7022
P8001
P8002
P8003
P8004
P8005
P8006
P8007
P8008

Component
Front Aluminum Bell Crank
Rear Aluminum Bell Crank
Front Upright
Front Knuckle
Front Tie Rod Mount
Rear Upright
Rear Knuckle
Front Blade
Front Bar Mounts
Front Sway Bar
Rear Blade
Rear Bar Mounts
Rear Sway Bar
Area Total
1 Piece Magnesium Wheels
Valve Stem
Tires
Front Hub
Front Sprindle
Rear Hub
Wheel Bearing
Wheel Bearing Spacer
Area Total
Total

Description
Aluminum Bell Crank
Rear Aluminum Bell Crank
Aluminum Bell Crank
Complete Front Upright Assembly
Aluminum Front Upright
Aluminum Front Knuckle
Aluminum Front Tie Rod Mount
Complete Rear Upright Assembly
Aluminum Rear Upright
Aluminum Rear Knuckle
Complete Front Roll Bar Assembly
Front Steel Blade
Aluminum Mounts
Steel Bar
Complete Rear Roll Bar Assembly
Rear Steel Blade
Aluminum Mounts
Steel Bar

Unit Cost
$
27.90
$
$
23.88
$
$
114.96
$
7.22
$
7.19
$
$
111.61
$
18.99
$
$
3.30
$
14.45
$
46.55
$
$
7.88
$
4.49
$
16.41

Complete Wheel Assembly

Student Built Magnesium Wheel
Purchased Valve Stem
Goodyear 2696
Front and Rear Hub Assembly
Aluminum Front Hub
Aluminum Front Spindle
Aluminum Rear Hub
Wheel Bearing Assembly
Wheel Bearing
Wheel Bearing Spacer

$
$
$
$
$
$
$
$
$
$
$

14.36
222.39
1.00
100.00
35.19
30.80
21.22
147.11
8.89

Quantity
2
1
2
1
2
2
2
1
2
2
1
2
2
2
1
2
2
2
1
4
4
4
1
2
2
2
1
2
2

Material Cost
$
10.19
$
$
3.07
$
$
26.29
$
1.15
$
0.83
$
$
26.25
$
4.15
$
$
1.60
$
9.99
$
40.10
$
$
2.13
$
0.01
$
10.69
$
1,835.47
$
$
59.16
$
1.00
$
100.00
$
$
7.56
$
7.10
$
13.73
$
$
146.87
$
3.07
$
997.30
$
9,124.03

Process Cost
Fastener Cost
$
14.64 $
3.07
$
$
$
17.74 $
3.07
$
$
$
87.59 $
1.08
$
5.53 $
0.54
$
5.55 $
0.81
$
$
$
84.19 $
1.17
$
14.18 $
0.66
$
$
$
1.70 $
$
3.87 $
0.59
$
5.12 $
$
$
$
5.75 $
$
3.89 $
0.59
$
4.39 $
$
586.93 $
44.88
$
7.96 $
6.40
$
158.23 $
$
$
$
$
$
$
$
25.55 $
2.08
$
23.70 $
$
5.41 $
2.08
$
$
$
0.24 $
$
5.82 $
$
762.32 $
14.72
$
2,954.42 $
165.29

Tooling Cost
$
$
$
$
$
$
$
$
$
$
$
$
$
$
1.33
$
$
$
$
1.33
$
64.01
$
$
5.00
$
$
$
$
$
$
$
$
$
$
20.00
$
183.96

$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

Total Cost
55.80
47.76
229.92
14.44
14.38
223.22
37.98
6.60
28.90
93.10
15.76
8.98
32.82
2,531.29
14.36
889.56
4.00
400.00
70.38
61.60
42.44
294.22
17.78
1,794.34
12,427.69

Details Page
Number
160
161
162
164
165
167
168
169
170
172
173
174
175
177
178
179
181
182
183
184
185
186
187
188
190
191
193
194
195