For our project, we were tasked with designing and building a vehicle by repurposing bike parts. Instead of taking the conventional route, my team decided to build a custom scooter from scratch. This allowed us to have full control over the design while optimizing for efficiency and endurance, as our goal was to perform well in the long-distance endurance category of the race. My primary responsibility was to design the physical CAD models and figure out how to properly integrate a drill-powered propulsion system into our scooter.

A major challenge was selecting and sourcing the right materials. We needed a lightweight yet durable frame, which led us to carefully evaluate different types of steel tubing. Additionally, we had to calculate torque requirements to ensure that our drill could effectively power the scooter. This meant analyzing gear ratios and choosing the right combination of sprockets and chains to optimize power delivery.

Testing and Adjusting the Drill’s Performance

The drill was the heart of our propulsion system, so we needed to determine whether it provided sufficient torque to move the scooter efficiently. While the manufacturer provided technical specifications, we quickly realized that these numbers were unreliable. Through our own torque testing, we discovered that the actual output was only about 60% of what was advertised. This finding forced us to make design adjustments, including modifying the gear ratio and reinforcing the mounting structure to prevent energy loss.

To further improve efficiency, we experimented with different battery configurations to extend the drill’s runtime. Managing power draw was crucial, as excessive strain on the drill could lead to overheating and performance degradation. These tests were time-consuming, but they ensured that our scooter would have enough power to complete the endurance race without failure.

Overcoming Manufacturing Setbacks

While our design worked well in theory, we encountered unexpected manufacturing issues that forced us to adapt. Some parts were incorrectly welded due to a miscalculation from a teammate, which meant rebuilding key structural components. Additionally, we had mistakenly ordered the wrong freewheel hub, which would have caused severe drivetrain inefficiencies.

To resolve the hub issue, we made the last-minute decision to weld the threads directly to prevent it from loosening. While not an ideal solution, it allowed us to keep the project moving forward. These setbacks reinforced the importance of double-checking specifications before ordering parts and emphasized the reality that engineering projects rarely go exactly as planned.

Race Day and Final Results

As the endurance race approached, we were still making final adjustments. In a dramatic turn of events, we completed the scooter the night before the race, leaving little room for extensive testing. Despite the challenges, we managed to get it running just in time.

During the competition, our scooter successfully completed two full laps around the lake, proving that our design and last-minute modifications paid off. While there were lessons learned about planning, testing, and manufacturing, the project ultimately showcased our team’s problem-solving skills and ability to adapt under pressure. This experience reinforced my passion for hands-on engineering and the importance of resilience in tackling real-world challenges.