Last week was the annual Supermileage competition hosted by SAE and Eaton in Marshall, MI. I joined Michigan Tech's Supermileage Systems Enterprise (SSE) last fall, and have been working on our vehicle for most of the school year. I decided to join the powertrain sub-team, and cut my teeth by helping to design a new rear end frame for our car. I also designed and built an engine mount that is both adjustable and makes it (relatively) fast and easy to remove and replace the engine, along with a device for properly tensioning the drive chain. As a final project before summer break I reconfigured the fuel system to take up less space and fit the new layout better. The fuel system also incorporated quick-disconnects to facilitate simple and fast engine removal, a major goal of the design this year.
Needless to say I was quite anxious to see this vehicle in action. During the year we almost never have the whole vehicle in one piece because we are making so many modifications. Competition was the first time I saw the whole thing working the way it was intended to. This was my first time being at a supermileage competition, and I got the swing of things fairly quickly. The team's first goal is to pass the technical inspection. We had to make some changes to our electrical system, because the officials were concerned about the safety of a few of our more advanced features. Luckily we could function without those systems working and quickly made it through that stage of technical inspection. We then had to pass some basic handling tests. That's when our starter broke.
Our team in line for technical inspection.
Without a starter our car was dead on the road, and we brought it back to our pit area and dug into the problem. It turned out that our starter bracket had cracked and broken at a weld. Unfortunately we didn't have a welder we could bring with us. Luckily our neighbors from South Dakota owed us a favor for borrowing our generator earlier, and they had a welder. It took a while for them to get used to welding on our aluminum bracket but they got it fixed before the end of the day. In our rush to try the newly welded bracket we plugged some wires into the wrong ports and got a surprise when our engine flooded with fuel in quite a spectacular manner! Luckily we discovered our careless mistake fairly quickly and got the car running a few minutes before we had to leave for the day.
Working on our car in our pit area.
The next morning we arrived early and got ready to finish the handling tests. As it turned out, our car ended up being one of the best handling vehicles in the competition. In every test the judges reaction was something like "Wow, I've never seen anyone do that so fast!" Once we cleared all the tests, we were able to get out on the test track and compete for mileage. We had predicted a performance of 55o mpg based on our 456 the year before and the improvements we made. On the first run an access panel flew open and stayed that way for most of the run, so we were flabbergasted when our result of 950 mpg was posted. Our vehicle managed to complete three more runs without incident (which is quite rare for the competition). We continued to tweak our settings and achieved ever improving mileages of 960, 1063 and a final 1140. That last performance was enough to put us in 2nd place overall, which was a very pleasant surprise for this being only our second year competing. I guess we're on the right track! I, along with the other new members on the team, am now very excited to get back to work and make more improvements before we come back to Marshall next year. Hopefully we will outperform our wildest hopes again!
Our car being rolled out to the track to begin a 9.6 mile run.
