Formula SAE Frame Assembly Guide
Michael Walker
The following build is the first step in creating a weekend autocross racer! Your final product will be
ready for other components and reading carefully will ensure a safe vehicle. An FSAE car can be
years of fun on and off the track.
Please read through the tools needed, skills need and warnings sections to verify your qualifications
for this build. This build will take between 3 and 6 weeks. At any point during the build you may
contact [email protected] for technical help.
Tools Required:
- Welder - Acetone
- Wire Wheel - Rags or Towels
- Tape Measure
- Level
- 12mm Wrench (2)
- Welders Triangle magnet
- Oxy/ Acetylene torch with Rosebud
- Sharpie
- CNC taped (1in X 1in) table or another 4ft X
8ft surface for bolting jigs and frame onto
Warnings and Liabilities:
Skills Needed:
- Working knowledge of: Danger: Serious injury or death can occur while
o Oxy/ Acetylene operating tooling. ALWAYS wear safety glass and
o Wire wheel check operator manuals before using any equipment.
o Basic measurement tooling
o Welding
- Strong technical skills are helpful during this All injuries during construction or any use of
build Formula SAE Frame by Michael Walker are the sole
responsibility of the purchaser.
Materials Supplied:
(BOM on last two pages)
- 64 Fully cut and notched frame members
- Reusable Jigging hardware
- Mounting Jigs and risers
o 5 square inside jigs
o 4 round inside jigs
o 4 5in I risers
o 3 2.5in block risers
o 1 adjustable Roll hoop and Shoulder harness bar Jig
Formula SAE Frame: 2
Section 1: Preparation
In this section you will prepare tubing and work surface for assembly.
Step 1.1: Step 1.2:
Wire brush the ends of the full tube set so that a Tape 6 lines on your work surface to help you during
inch of each tube is cleaned off. assembly.
You have now completed the Preparation get ready for the Assembly Process.
Section 2: Assembly
Unless instructed otherwise follow each step that follows tack all joint assembled. Be sure to re-measure all
tube locations after welding to ensure proper fit. (Tip: The last page of this manual is a full drawing and part
number labeled schematic)
2.1 End boxes and Bottom: 2.1.2 Rear box
2.1.1 Front box Using Jigs A1-3 again jig 001, 046 and 047.
Using Jigs A1-4 to mount tubes 042-045 to the table
as below and fully weld.
2.1.3 Rear box 2.1.4 Lower Rear box
Now slid 049, 001, 048 and 034 in that order into Using your welders triangle and jigs A1-3 to make
place and fully weld the completed rear box. sure the rear box is 90 degrees from the table jig
072, 001 and 008 to the table as below.
Formula SAE Frame: 3
2.1.5 Lower Rear box 2.1.6 Lower Front box
Without removing jigs slide 051, 050, 052 and 035 Using your welders triangle again to ensure the front
into place in that order and fully weld. box welded earlier is 90 degrees from the table. Jig
043, 005, 004 and 003 using A4 and B1-3
respectively.
2.1.7 Bottom
2.1.8 Bottom
Using your tape lines you laid out earlier as
Slide 053, 055, 054, 009 and 010 into place in this.
reference Jig welded Lower Front box over the first
two lines with Jigs A4 and B1-3 along with riser C1-4.
Do the same thing with the Lower rear box over the
back most two lines using Jigs A1-3 and block risers
D1-3. Jig 006 to the middle line using Jigs B4-5.
2.1.9 Bottom
Now to finish off the bottom of the frame put 036 and 037 into place and fully weld any non-welded joints.
2.2 Main Rollhoop and Back 2.2.2 Main Rollhoop supports
2.2.1 Main Rollhoop Measure down from the top of 038 4.88inches and
Using Jig E and a level fix Main rollhoop 038 into make two marks on the tubes. Following this place
place at a 90 degree angle from the table and on top 056 and 057 where the tops touch the line and the
of 006. bottoms sit on 035.
Formula SAE Frame: 4
2.2.3 Crosslink of supports 2.2.4 Upper Rear box
Measure 13 inches up from the table and mark on Now complete the rear box by fitting 023 and 024
both support members. Now slide 033 between the into place where they hit the main supports along
supports till the top of both sides are at your marks. with 033 and 034.
2.2.5 Engine Bay
Complete the engine bay by adding 060, 061, 022 and 039 in this order.
2.3 (Front Rollhoop and Forward): 2.3.2 Front Rollhoop supports
2.3.1 Front Rollhoop Measure from the ground up to the Front
Using Jig E to hold the front rollhoop 031 at a 70 Rollhoop 23.5 Inches and make two marks. Follow
degrees from the ground and positioned on 009 and this by placing 011 and 012 where the tops of the
010 as indicated below. tubes hit these lines and the other ends land on the
corners of 045.
2.3.3 Front box
Now measure 10.5 inches over from the front of the
frame on both 005 and 003 and make a mark. Now 2.3.4 Front box
place 014 and 018 where the front of the tube hits Place 015 and 019 at the corners of 003, 004 and
the line. Both should be angled out slightly as shown 005 at a slight angle as shown below.
below.
Formula SAE Frame: 5
2.3.6 Front box
2.3.5 Front box Continuing with 088, 091, 029 and 030 in this order
Place 013, 017, 090, 093, 027 and 028 in this order. into place.
2.3.7 Front box completion
By placing 089, 092, 016 and 020 in this order you have completed the front box.
2.4 (Side impact and Details) 2.4.2 Shoulder Harness Bar
2.4.1 Side impact Using Jig E again fix 032 37.5 inches parallel from the
Locating and placing 026, 065, 040, 021, 041 and ground where the ends locate on the Main
025 in this order completes the side impact. Refer to Rollhoop 038.
below dimensions for more details.
2.4.3 Suspension Mount bar 2.4.4 Frame Stiffening bars
Placing 058 and 059 as indicated below completes To complete the assembly section place 062 and 063
the suspension mounting points. 3.6 inches from the center of 006 and hits the joint
of 038, 039 and 022 with the top.
Assembly Completed
Congratulations you have made it through the hard part of the build. You will want to Fully weld all joints
before continuing on to the next step. Make sure to leave all Jigs in place through the Heat Treating process
you will do next.
Formula SAE Frame: 6
Section 3: (Heat treating and Finishing)
In this section you will heat treat the frame and clean all oxidation off weld points.
3.1 Heat Treating 3.2 Cleaning
Using the Rosebud on the Oxy/ acetylene torch After waiting 2 hours for the Frame to cool using
evenly heat each joint until you see blue lines form acetone and a rag, wipe down the whole frame to
in which you will want to move away from the joint. clean all weld joints and tubes.
(Tip: The metal is to hot if it has turned red, also be
sure to go from one side of the frame to the other
working you way to the back.)
Completion
Your frame is now welded, heat treated and cleaned you can now remove all Jigs and proceed with
completing your weekend autocross racer. For more information and assistance with your frame contact
[email protected] at any time.
Materials Supplied
Jig A Jig B Jig C
Jig D Jig E
Formula SAE Frame: 7
