Hands-On Approach to Vehicle Design and Fabrication by Budding Engineers

Abstract: This paper outlines the detailed process involved in designing and constructing a budget-friendly, lightweight vehicle using commonly available materials and components. The primary objective was to enhance hands-on engineering skills by applying core concepts from mechanics, thermodynamics, material science, and manufacturing methods. The project began with initial sketches and CAD modeling, leading to the construction of a tubular frame chassis made from mild steel. A 150cc Bajaj Pulsar engine was chosen for its compactness and dependable performance, with power delivered to the rear wheels through a chain drive system. The body was fabricated using umbrella cloth, selected for its light weight and flexibility, contributing to cost reduction. Custom-built suspension, steering, and braking systems were designed and installed based on specific project needs. The entire vehicle was assembled using standard tools available in a college workshop. Upon completion, the car was tested and showed reliable performance under typical driving conditions. This paper covers every phase of the build, highlighting the obstacles encountered and the practical solutions implemented. Keywords: Design, Fabrication, Chassis, Engine, Suspension, Prototype, Umbrella Cloth