2009 Rules

I General

The objective of the competition is to provide Indiana high school students with a challenging and educational activity combining the theoretical aspects of mathematics, science and technology with practical experience in design, fabrication, and testing of an actual vehicle.

In an effort to increase public awareness in the area of fuel economy, a fuel economy challenge will be held. Participating students will be challenged to build a one man, fuel-efficient vehicle powered by a single cylinder four-stroke cycle engine. The vehicles will run a specified course with the vehicle obtaining the highest miles-per-gallon rating winning the challenge. Other awards will be given for best integration of Mathematics, Science and Technology into the design and construction of the vehicle, best design, craftsmanship, sportsmanship, teamwork, closest to estimated performance and best communication and marketing program.

This challenge is designed as an inter-disciplinary unit for Mathematics, Science and Technology. The lessons involved in the design and construction of this vehicle are unlimited for creative students and teachers.

Design and construction of the vehicle is intended to be a student project performed by the students under the guidance and supervision of adult faculty members and/or parents. Parts and components fabricated by non-students should be kept to the minimum. Where outside facilities must be used, the instructors should ask those facilities to allow maximum student participation or, at the least, request that they provide explanations of the operations involved and allow students to observe the process.

II Organization

The Super Mileage Challenge is sanctioned by the Indiana Department of Education and the Indiana Mathematics, Science and Technology Education Alliance (IMSTEA) and is conducted under the supervision of the IMSTEA Competition Committee. The Competition Committee shall have complete authority over all phases of the event including the establishment and publication of rules governing the event. The Competition Committee shall consist of the President of IMSTEA and those persons appointed by the President from time to time. Membership in IMSTEA is not required to serve on the Competition Committee. In any dispute, protest or inquiry, the decision of the Competition Committee will be final.

III Classes of Competition

Two classes of competition are provided, Stock and Unlimited.

In the Stock class, engines are provided to the participants and must be maintained in strictly stock condition. No modifications are allowed. The engines will be sealed prior to delivery to each team, and any evidence of tampering with the seals may result in disqualification.

Engine modifications are allowed in the Unlimited class. The allowed modifications are spelled out in another section of these rules.

Only one entry is allowed in each class for any school. A school may not enter the Unlimited class unless they have previously participated in one event in the Stock Class.

IV Proposal

In order to be approved for participation, each school must submit a separate, detailed proposal for each class entered. Proposals must be postmarked no later than the deadline date established by the Competition Committee. Upon approval of the proposal by the IMSTEA Competition Committee, the team will be issued a number and allowed to participate in the Super Mileage Challenge. A non-refundable entry fee in the amount established by the Competition Committee must accompany each proposal. Teams will be allowed an opportunity to correct problems with their proposals after initial review, but must be able to do so before the revision deadline date established by the Competition Committee.

The proposal must be printed or typewritten in a minimum of 12 point type on plain, white, 8.5 inch by 11 inch paper and bound in a flexible binder or three ring binder. Computer generated text and drawings are permitted, but no large or outsize drawings should be included unless absolutely necessary to explain some unusual aspect of the proposed design.

The design proposal serves two purposes. First, it is an information document allowing the Competition Committee to determine that the vehicle design conforms to the rules. Second, it ensures that the entry is a result of a genuine design effort integrating math, science, engineering and technology.

Please Note: The proposal may be for a design concept and does not have to reflect the vehicle as actually built. At the time of technical inspection, the team must present to the inspector, in writing, descriptions of those areas where the finished vehicle differs from the conceptual design of the proposal.

A proposal will consist of the following sections:

Title Page

The first page of the proposal must contain the following information:

School name and address.

Class the proposal covers (Stock or Unlimited)

Full name of the lead faculty advisor.

Phone number of the lead faculty advisor.

Email address of the lead faculty advisor.

FAX number of the lead faculty advisor.

Full name of the Science faculty advisor.

Phone number of the Science faculty advisor.

Full name of the Mathematics faculty advisor.

Phone number of the Mathematics faculty advisor.

Full name of the Technology faculty advisor.

Phone number of the Technology faculty advisor.

Full name of any advisor from the community, if applicable

Phone number of the community advisor

Date the proposal is prepared.

(Note: The lead faculty advisor may also serve as one of the other required advisors.)

Section I – Design Concept

This section gives an overall description of the design and outlines any unique or unusual aspects of the proposed design.

This section must include a dimensioned drawing of the proposed design showing the outside configuration including the positioning of numbers and location of windows if a closed body is used. This is comparable to photos of the finished vehicle from the side, front, top and rear.

If a vehicle from a previous year is being used, this section must include a description of the changes made from the previous year. This may be a general discussion with details described in later sections dealing with those systems.

Section II – Frame/Chassis

This section must describe how the frame/chassis of the vehicle is to be built. It must describe the materials and the methods to be used in fabricating the frame/chassis. This section must also detail any participation by any person or firm outside the school.

This section must include a three view, dimensioned drawing of the frame/chassis without the body or other components attached. If the vehicle does not have a separate body, the placement of the numbers must be shown on this drawing.

Section III – Body

This section will describe the materials and methods to be used in fabricating the vehicle’s body. If the vehicle will not use a body, this section should state that fact.

This section must also detail any participation by any person or firm outside the school in the design or construction of the body.

A three view, dimensioned drawing of the body must be included, and this drawing must show the location of all transparent portions of the body. This drawing will also show where the numbers will be placed. If there will be no body, the method of number placement must be shown on the drawing of the frame/chassis.

This section must describe how the body will be attached to the chassis/frame, and how the driver will gain access to the vehicle if the body is closed.

Section IV – Drive Train

This section must include a thorough discussion of the method of driving the vehicle from the engine.

A three view, drawing of the drive train must be included.

For Unlimited proposals, this section must also describe, in detail, all modifications proposed for the engine. If none are planned, the proposal must state this fact.

Section V – Braking System

This section must include a discussion of the proposed braking system for the vehicle.

A three view, drawing of the braking system must be included showing the braking system for each wheel where brakes are installed and the method for driver actuation of the brakes.

Section VI – Fuel System

This section must show a drawing of the fuel system to be used in the vehicle including the location and means of mounting the fuel tank, the length of the fuel line in inches and any provisions for fuel cooling or heating.

For unlimited entries, this section must list the carburetor to be used by model number and manufacturer or state that the stock unit will be used. Carburetors with oversized float chambers are not allowed. Fuel pumps are permitted, but no device that may act as an accumulator is allowed.

This section must also show how the driver is prevented from reaching the fuel tank while in the vehicle.

If fuel injection is used in unlimited entries, this system must be diagramed and manufacturer and model number of components must be included. Any flexible hose used on the high pressure side of the fuel pump must be aircraft type high pressure fuel hose with aircraft style fittings.

Section VII – Steering System

This section must discuss the means to be used to steer the vehicle and include diagrams and/or calculations showing that the design will meet the turning radius requirement of these rules. Please note that a steering wheel system must be used. Tillers, steering bars or other systems are not permitted.

Section VIII – Safety

This section must include a three-view drawing showing the location of all required safety equipment. Any additional or unusual approaches to safety must also be discussed. The material and thickness of the firewall must be listed in this section.

This section must show how the driver will be seated in the vehicle and show that such seating conforms to all rules listed herein.

If a closed body is used, this section must also discuss the means of driver emergency exit from the vehicle, means of providing for ventilation for the driver’s compartment and means for routing engine exhaust gases outside the body.

This section must show how the minimum driver weight will be achieved. If weight belts will be used, this should be stated. If ballast weights will be added to the vehicle, this section should include a reference to a drawing showing that the system for adding these weights conforms to the rules

Firewall material and thickness must be specified in this section.

Section IX – Aerodynamics

This section must include a discussion of the aerodynamic qualities of the vehicle. It must include a calculation of the vehicle’s aerodynamic drag showing the value of all factors involved and the equation used for the calculation. The impact of headwinds, tailwinds and crosswinds must be evaluated.

Section X – Cornering Forces

This section must include a discussion of the impact of cornering forces on the vehicle. Calculations must be shown for anticipated cornering forces

Section XI – Braking Distance

This section must include calculations showing the anticipated braking distance for the vehicle. The calculated distance must be less than the figure allowed in these rules.

Section XII – Rolling Friction

This section must include a discussion of the factors contributing to rolling friction and describe any testing procedures planned to determine rolling friction. Means of reducing rolling friction must also be discussed.

Section XIII – Performance

This section must include a discussion of driving techniques to be used in the competition. Best speeds, engine parameters and any instrumentation to be used will be included in this section. An estimate of the vehicle’s performance in miles per gallon must be included.

Section XIV – Accessories and Instrumentation

This section must describe all accessories and instrumentation to be installed in the vehicle besides the components previously mentioned. The purpose and operation of each unit must be described in detail.

For unlimited vehicles, this section must include a complete drawing and description of the electrical start system, if used. It must also describe how the system will be disconnected from the drive system so that it may not be used to power the vehicle.

Section XV - Cost Estimate

This section will include a detailed cost estimate for the design and construction of the vehicle. All parts, purchased or manufactured, must be shown. Any services obtained must be listed at quoted cost. Items donated must be listed, but no cost figure is required. Donated items must be identified as such. This is an estimate. Exact figures for every nut and bolt are not required, but it should reflect at least 85% of the vehicle’s final cost.

Section XVI - Marketing, Promotion, Public Relations & Communication

In an effort to improve and enhance the language arts and communications skills of students, IMSTEA has added this new section to the design proposal. This section of the proposal requires that the details, action plans and timelines of student SMC marketing efforts be developed to help communicate the benefits of the SMC to the public across the state and nation.

Example activities may include, but are not limited to, samples of team created promotional materials, brochures, web pages, public demonstrations, letters, press releases, magazine features, promotional videos, flyers, letters of invitation to the public, parents, decision makers and/or potential local team sponsors.

The intent of this section is for students to demonstrate their “above and beyond” efforts to help communicate the positive benefits of the SMC to the community, potential sponsors and media throughout the state of Indiana and the nation.

To qualify for the SMC marketing and promotion award, teams must submit

a portfolio that documents their marketing plan with a timeline of events and samples/

documentation for evaluation received 14 days prior to the event for review by

IMSTEA.

V Rules Governing the Vehicle

A. General Configuration:

1. The vehicle must have a minimum of three wheels touching the ground at all times. Tandem, two wheel configurations with outrigger wheels are prohibited. Also prohibited are configurations where any part of the driver extends beyond the frame of the vehicle; i.e. bicycle or luge style designs.

2. Overall vehicle length, width, and height will not be regulated. However, the distance between the centerline of wheels on any axle (track) may not be less than twenty inches (50 cm), and the distance between the front and rear axle centerlines (wheelbase) must be at least 1.5 times the front track.

3. The driver’s head must be behind his/her feet in the normal driving position.

4. Design shall be such that the driver may not come into contact with a wheel or any other moving part while in the normal driving position. If the wheels are inside the body shell, they must be shielded to prevent manual propulsion by the driver.

5. The fuel tank must be located in such a position that it will be impossible for the driver to shut off the fuel valve while operating the vehicle or to make any adjustment to the height of the tank. Electrical fuel shut off valves are not permitted. The copper screen in the fuel valve provided with each tank must be in place and intact. Removal or damage to the screen may result in disqualification.

6. Each vehicle will be assigned a number. This number must be displayed on both sides of the vehicle. The numbers must be painted a contrasting color to their background. Black numerals on a white background are preferred. Unlimited class entries will be followed by a capital letter “U”. The numerals must be at least 10 inches tall, and the capital “U” for the unlimited class will be six (6) inches tall.

7. Vehicles used in previous events may be used in subsequent events providing modifications acceptable to IMSTEA are made from year to year. Repainting the vehicle is not considered to be a significant modification.

B. Maneuverability: Each vehicle must have a steering geometry capable of a 25 foot maximum inside turning radius for either right hand or left hand turns measured at the most outside wheel in the turn. Vehicles must use steering wheels. No tillers, steering bars, steering cables or foot actuated steering devices will be allowed. Steering wheels must have a minimum outside diameter of eight (8) inches and function in a conventional manner. “Bow Tie” units are permitted.

C. Stability:

1. Each vehicle will be required to demonstrate its longitudinal stability. The vehicle, with the qualified driver in driving position, must maintain full wheel contract on an

inclined plane (ramp) of 15 degrees (measured from horizontal) when located statically on the inclined plane in the following configuration.

2. Two ramps will be used, one for the front wheel(s) and one for the back wheel(s). The vehicle will be placed so that all wheels are in contact with the ramp surfaces. If the track of any axle is too wide for the ramps, one wheel may be placed on the horizontal floor surface as close to the edge of the ramp as possible. No supporting structure or wheel may contact the inclined plane or horizontal floor surface.

3, The vehicle must not tip or lose balance when the steering wheel/wheels are to turned lock to lock. This test will be performed with no help to stabilize from the pit crew.

D. Engine:

1. Stock Class.

a. All vehicles are required to use air cooled, four-stroke cycle Briggs and Stratton model number 93412 engines.

b. The engine must be box stock! This means no electric start, the governor must remains on the engine (attached and working), no air filter removal (including the canister) or changes, and no changes in exhaust (the stock muffler must remain in place). However, an extension after the muffler to exhaust fumes out of the vehicle and away from the driver is permitted. An alternate muffler may be installed using “Max Power” part number 4132 or Briggs & Stratton part number 89966 in place of the stock muffler. If an alternate muffler is used, it must be positioned at the exhaust port of the engine. Repositioning of the recoil starter housing and lengthening of the recoil starter rope to suit engine and driver position to provide for re-starts by the driver are also allowed. No other changes, additions, subtractions or improvements are allowed. Alternative spark plugs may be used, and any type of oil may be used in the engine.

c. The 93412 engine will be modified prior to delivery and sealed. Any entrant on which the engine seals have been broken or tampered with in any manner will be considered for disqualification.

d. Briggs & Stratton high altitude jets may be used in stock class carburetors. These jets are part number 494870 (after code date 96032400) and 497466 (before code date 96032500).

2. Unlimited Class

a. The unlimited class may utilize either the model 90102 (black) engine or the model 93412 (red or silver) engine.

b. The unlimited class engine must retain the cylinder block, crankshaft and crankcase of the stock engine. The crankshaft must also occupy its original position in the crankcase, and the deck height of the cylinder block (the distance between the center line of the crankshaft and the mating surface of the cylinder head with the block) must remain the same as the stock engine. Any other parts may be removed, modified, replaced or homologated as desired.

c. Electric start is permitted in the unlimited class, however there must be no provision for driving the vehicle with the starter motor. Batteries to be used for electric start will be limited to the capacity needed to start the engine.

d. Carburetors with oversize float chambers will not be allowed.

e. No device which acts as an accumulator may be added to the fuel system.

f. If fuel injection is used, the line from the tank must connect directly to a one-way check valve allowing flow only into the fuel pump. This valve must be mounted as close as possible to the fuel pump. All high pressure lines must be aircraft high pressure fuel lines with metal, aircraft style fittings.

E. Additional On-Board Equipment: Batteries may be carried in each vehicle to power auxiliary systems i.e. tachometers, recording devices, indicators or communication equipment (starters on unlimited class). They must in no way be capable of powering the vehicle. The sole source of vehicle propulsion must be from the engine. This means no human power system, sails, etc. Any inertial system, if used, must be at rest prior to the start of any performance runs. Any vehicle found in violation of this rule may be eliminated from competition and any completed runs may be forfeited.

F. Fuel: The fuel used will be furnished by the competition committee to provide uniformity in the composition. Fuel tanks must be obtained from the IMSTEA competition committee and may not be modified except to provide for adequate tank venting.

G. Drivers:

1. Only two drivers are permitted for each vehicle. Teams will furnish driver names on their team rosters, and only those designated drivers may operate the vehicle. If a driver substitution is necessary before technical inspection, the Faculty Advisor will advise the Competition Committee of that change during registration. Should a driver substitution be needed during the event, the Faculty advisor will obtain permission for that substitution from the Competition Committee.

2. Minimum driver weight is 150 pounds(68Kg.) Fully equipped, including helmet.

3. Drivers who do not meet the minimum weight requirement must provide ballast to bring their weight up to the 150 pound base limit.

a. Ballast may be attached to the driver or to the vehicle and may not be removed during actual competition (see later design provisions).

b. When the weight is attached to the driver it must be in the form of a diver's belt.

c. Weights must be either circular barbell weights or lead bars. For barbell weights, a vertical post of sufficient diameter to match the in