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Project Overview
As the Team Leader of the Texas A&M University ASME Go Kart Team, Midnight Rev, I lead a 15-person team to design, analyze, and fabricate a fully functional go-kart. The project challenged us to balance speed, handling, safety, and budget constraints while applying engineering principles in a hands-on, real-world context. From brainstorming and CAD modeling to welding and assembly, this project gave me the opportunity to strengthen my technical, problem-solving, and teamwork skills.
Design and Planning
Our team began by establishing key needs and requirements for the kart. It had to function safely and reliably, ride comfortably with minimal vibration, maneuver quickly, achieve adequate speed, and remain structurally sound under load. Additional priorities included an emergency kill switch, easy driver evacuation, and a torque converter for smooth acceleration.
To meet these goals, we implemented several core design strategies. The frame was designed with a low center of gravity by positioning the tubing below the wheel centers, which improved both stability and speed. We incorporated Ackermann steering geometry by adjusting spindle mount positions and optimizing tie rod lengths to improve steering precision and cornering ability. A shorter wheelbase was chosen to enhance agility, allowing the kart to navigate tight turns more effectively. Structural integrity was confirmed through finite element analysis of the frame under the combined loads of the driver and components, ensuring durability under operating conditions. The initial CAD models and simulations allowed us to refine dimensions, test geometry, and balance trade-offs between stability, speed, and strength before moving into fabrication.
Fabrication and Assembly
The fabrication process required extensive use of machining and welding skills. I contributed to cutting and preparing A36 steel tubing, grinding edges, and performing MIG welds to construct the frame. The lowered chassis design depended on precise angular welds, which were critical to ensuring both strength and stability.
After the frame was completed, we moved into subassemblies. The rear axle and engine mounts were installed to hold the Predator 212cc engine with a torque converter, which powered the live axle through a chain drive. The steering system was assembled with the column, spindle brackets, tie rods, and steering wheel, carefully aligned to maintain Ackermann geometry. The seat and pedals were positioned for driver comfort and ergonomics, and a hydraulic braking system was integrated for safe and reliable stopping. Finally, the front wheels and spindle brackets were installed and adjusted to set camber and track width, further refining handling and responsiveness. Throughout this process, the team carefully documented fabrication and assembly steps to ensure consistency and record design decisions.
Testing and Iteration
Once assembled, the kart underwent several rounds of testing to evaluate its performance. Early tests revealed braking and steering alignment issues, which were corrected by adjusting pedal resistance and modifying tie rod connections. The torque converter also required tuning to optimize acceleration. After these refinements, the kart demonstrated smooth acceleration, stable handling, and reliable braking performance. The implementation of Ackermann steering and a short wheelbase design made cornering more agile, while the lowered chassis provided stability at speed. The final product met our goals of speed, maneuverability, safety, and structural durability, validating our design choices and fabrication methods.
Testing also highlighted the importance of iterative problem-solving and teamwork. Each round of driving exposed new areas for improvement, from drivetrain adjustments to comfort refinements for the driver. By quickly diagnosing issues and applying targeted fixes, the team was able to enhance the kart’s performance in a structured, step-by-step manner. This iterative process reinforced the value of testing not just as a validation step, but as an essential part of engineering design that drives innovation and ensures reliability in the final product.
Reflection
This project reinforced my ability to integrate theoretical engineering principles with hands-on application. I gained experience in CAD modeling and FEA analysis, which were critical in validating design choices before fabrication. My technical skills in welding and fabrication improved significantly as I worked on MIG welding, precision cutting, and assembly of the frame and components. I also became more comfortable with mechanical system assembly, including drivetrain, braking, and steering components, and learned how to identify and resolve issues through iterative testing.
Beyond technical skills, this project highlighted the importance of collaboration and communication. Working with a large team required coordinating design trade-offs, delegating tasks, and ensuring subassemblies were compatible. By combining the strengths of different team members, we were able to bring together a cohesive final product that reflected both strong engineering fundamentals and practical problem-solving.
The Midnight Rev go-kart project was one of the most impactful experiences of my time at Texas A&M. It combined design, analysis, fabrication, and testing into a single comprehensive challenge that mirrored the realities of professional engineering projects. Through this experience, I grew as both a designer and a fabricator, while also learning how to collaborate effectively in a large team setting. Most importantly, I saw firsthand how a concept could be transformed into a fully functioning product through creativity, precision, and teamwork.
Photos and Final Presentation
Final Go Kart Presentation 24-25.pptxPage updated
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