Reverse Engineering and Component Redesign

[Lemon98]

Hi everyone,

I have the opportunity to reverse engineer and redesign any part or component for my motorsport engineering dissertation.

I need to choose a part/component so are there any suggestions from you guys? Something you wish could be better?

I will need to have a physical version to then create a model, simulate it's forces/functions and then redesign it to be lighter, more efficient, reliable, increase performance etc.

So anything from the airbox to the window mechanism. Literally anything!!


Please give me some ideas!!!! As I will own the intellectual property I can share the design/model that I come up with for you to find someone to make it!!

[Satan]

One touch electric window switch or a vert switch that drops the window when you pull the door handle like on the E36.

[coopman]

Interesting project. Are you more interested in mechanical or electrical stuff?

My engineering dissertation looked at design for assembly (DFA), i.e. redesigning components to simplify the assembly process. The E30 is a relatively simple vehicle, but in my experience there are plenty of parts that are a total pain in the arse to remove/refit - room for improvement!

[Lemon98]

Interesting project. Are you more interested in mechanical or electrical stuff?

My engineering dissertation looked at design for assembly (DFA), i.e. redesigning components to simplify the assembly process. The E30 is a relatively simple vehicle, but in my experience there are plenty of parts that are a total pain in the arse to remove/refit - room for improvement!

More of the mechanical side really. The supervisor is looking more for improving the individual function for that particular component and less so how it relates to others.

So I spoke to him briefly about the window motors and he suggested that I could create a servo that allows the window to drop really quickly on a different set of gears and the servo switches them back to generate sufficient torque to push the window back up.

A couple years ago someone modelled the airflow of an R32 GTR race car airbox so I could easily do our e30 one or the intake/exhaust manifold. I'm quite interested in the exhaust manifold because all of the good 6 branch ones that actually fit are horrifically expensive.


I need to check out more of the projects because Hiroki Toyoda now works at my uni. He designed the SR20, RB26 etc and even Honda's F1 engines!!

[Satan]

Interesting project. Are you more interested in mechanical or electrical stuff?

My engineering dissertation looked at design for assembly (DFA), i.e. redesigning components to simplify the assembly process. The E30 is a relatively simple vehicle, but in my experience there are plenty of parts that are a total pain in the arse to remove/refit - room for improvement!

Remember when it was designed to see the bigger picture,

[Satan]

Out of interest which direction are you planning on following in engineering?

[Lemon98]

Out of interest which direction are you planning on following in engineering?

I'm very much attracted to historic racing teams and engine building/restoration or modern race engine building and tuning. There are a few companies that do everything from ground up resto's to race prep and running to events like the Mille Miglia and the Coppa Della Alpi, I like being close to the client side of things and get more from seeing smiles and making people happy than winning a championship.

So something a bit like this


Anything that has an aspect of physically working with my hands and not being stuck behind a computer every day looking at data.

That probably makes sense seeing that I drive an E30 and have had classic minis before

[Lemon98]

I am submitting my proposal for the project now and listing the heater blower, windscreen wiper motor and window regulator motors to then choose one to reverse engineer and redesign.

Wish me luck guys!! I'll keep you updated with which project I get as I have applied for a couple of others as well.

Cheers for the recommendations

[BristolE30]

Interesting project. I wonder if there’s a way to redesign something like subframe bushes, make them easy to replace instead of incredibly difficult. They effect ride feel a lot and are never changed because of tricky they are to replace

Although you might start getting into redesigning the whole vehicle then

[Shutthatdoor]

What a great opportunity to explore and learn by.
One thing that would genuinely be worth looking at for its failure rate on all models would be the windscreen wiper mech on e34s, the spindle the arms sit on have too much movement & this causes the arms to interfere with the bonnet. No solution to it so far other
Best of luck and keep us posted

[Satan]

Out of interest which direction are you planning on following in engineering?

I'm very much attracted to historic racing teams and engine building/restoration or modern race engine building and tuning. There are a few companies that do everything from ground up resto's to race prep and running to events like the Mille Miglia and the Coppa Della Alpi, I like being close to the client side of things and get more from seeing smiles and making people happy than winning a championship.

So something a bit like this


Anything that has an aspect of physically working with my hands and not being stuck behind a computer every day looking at data.

That probably makes sense seeing that I drive an E30 and have had classic minis before

This may interest you then down in Liss, also check out pre 1939 race cars and Edwardian racing, some amazing machines powered by aero engine like the Beast of Turin........

http://vintagebentley.com




Check out Mike Vardy and Richard Scaldwell.

[Satan]

Beast of Turin, 4 cyl 28.5 lts

[Moz]

Great project and opportunity! I second the suffrage redesign, possibly to match more modern set ups.

One touch window is available https://www.e30ig.com/#2thing

I've not got some yet but will be trying these for sure.

Thanks

[Lemon98]

I've been offered the part redesign and have the option of choosing which component still.

I'm waiting to hear back from our engine supervisor as he's also interested in working with me to increase power from the B20/ redesign the rockers to have roller tips/ AFM to MAP conversion and subsequent tune/ exhaust manifold design etc. Told him my aim was to get 2.5l power from the 2l.

If I can do a powertrain project I think I will choose that.... you can take a look at this credentials here https://www.linkedin.com/in/hiro-toyoda-ba644878/


Either way I won't be starting the project till after christmas, we just have to choose and get our projects confirmed now.