Vu motorsports intake exhaust team final presentation
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VU Motorsports Intake/Exhaust Team Final Presentation. Kristina Kitko Mark Melasky Perry Peterson Tim Wranovix. Project Description. Design and build a new intake and/or exhaust system for the 2008 Formula SAE racecar

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VU Motorsports Intake/Exhaust Team Final Presentation

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VU MotorsportsIntake/Exhaust TeamFinal Presentation

Kristina Kitko

Mark Melasky

Perry Peterson

Tim Wranovix

Project Description

  • Design and build a new intake and/or exhaust system for the 2008 Formula SAE racecar

  • Prepare a design report to be used in the FSAE 2008 Competition in Detroit

Problems with Current Naturally Aspirated System

  • Inadequate data describing the intake and exhaust systems

    • FSAE team has suffered at competition due to lack of presentable data

    • FSAE team is unable to make improvements to current system due to lack of appropriate testing and modeling

Problems with Current Naturally Aspirated System (cont’d)

  • Intake was made from spare parts in one day

  • Exhaust system is very heavy

    • FSAE team is using the stock muffler from the Honda motorcycle (8.5 pounds)

    • Total system weighs around 25 pounds


  • Described in FSAE rules:

    • 20mm Venturi restrictor on intake

    • 110 dB max exhaust volume

  • Packaging:

    • Fit within rear of car

    • Air filter, throttle, restrictor, fuel rail and muffler mounts

  • Cost:

    • Team must report market values of components used


  • Finished intake and/or exhaust system that is ready to be mounted on the 2008 FSAE car by April 1.

  • Detailed design report

    • Technical data with flow modeling

    • Images


  • Naturally Aspirated

    • Build intake and/or exhaust

  • Turbocharged

    • Build intake and exhaust


FSAE engine is setup for natural aspiration

Cheaper than forced induction system

Intake and/or exhaust can be redesigned

No moving parts, so less likely to fail

Not pressurized


Less power than complete forced induction

Geometry needs to be thoroughly calculated

Natural Aspiration


Increased power

Intake and exhaust are designed as one system

Simpler geometry compared to a naturally aspirated system

Widens engine’s power band




Turbo lag

Current FSAE high compression pistons need to be replaced

Too much power makes the car harder to drive


Competition Scoring

Turbos in Competition

  • Intake system data for 93/108 teams

    • 82 teams had natural aspiration

    • 11 teams had turbos

  • Overall placement

    • 6, 11, 14, 16, 45, 50, 53, 54, 57, 86, and 95

Schools with Turbos

  • Design is scored out of 150 points

    • 100 points is tied for 14th with 24 cars

    • 80 points is tied for 38th with 30 cars

    • 60 points is tied for 68th with 26 cars

    • 40 points is tied for 94th with 10 cars

  • Top cost score is 93.31

  • Engine Placement

    Front of Car

    Intake Ports Interface

    Exhaust Ports Interface


    General Intake Requirements

    • Air filter mount and scoop

    • Throttle body redesign

    • Venturi optimization

    • Plenum volume optimization

    • Velocity stack design

    • Fuel injector positioning and mounts

    3Y 4-to-1Dual Muffler

    Potential Exhaust SetupFiring Order 1-2-4-3

    Next Step

    • Proceeding with a Naturally Aspirated System

    • Begin modeling an intake system

    • Begin modeling an exhaust system

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