The construction of the frame of the 2010 Baja has been successfully completed; its dimensional accuracy of +/- 0.065 [in] was achieved through the use of wooden jigs used to support the individual members during construction. Furthermore, the weight of the 2010 frame was reduced by approximately 10 [lb] from the previous year’s frame.

Currently, the suspension and steering sections are waiting on parts to arrival before they may complete their assemblies. However, the delay in component arrival has not stopped this section from being productive; the tube structures of the front A-Arms have been tack welded and are currently supported in jigs. Also, rear A-Arm fabrication will soon begin.

Upon arrival of the gearbox, the powertrain design got into full swing in November, since then the entire rear end design has fallen into place. The addition of a simplified chain tensioning system and more serviceable configuration are highlights of the design. Construction of the powertrain can begin now that the frame has been completed.

Once the frame was completed from the roll hoop forward, the pedal assembly was installed. The assembly was designed such that most of the components were able to be laser cut and fully assembled upon their arrival. The use of bearings and sintered bronze bushings has significantly reduced the friction in the system and made it much smoother.