G’day EvilElmo
I’m in the process of designing a car from scratch and it’s a bitch. You need alot of time and alot of patience.
Firstly you should decide what sort of car you would like to design, road or race car, for example:
Group B rally car
Le Mans Prototype 675/900
Road/Sports car e.g Lotus Elise
Replica e.g. 60’s Ferrari/Aston Martin
Clubman type vehicle.
Or something that doesn’t fit into those categories.
Look up the Australian Design Rules so you know what the design must include.
Find out what materials your school will pay for and how much they will pay. They should cover simple materials like tubing for chassis construction but they won’t pay for the engine, brakes or other specific automotive parts and possibly not even Fiberglas or paint.
The following includes a list of useful engineering books and some websites.
The Gmecca site will help in telling you what components you need, so you can search for prices, and tell you what parts of the vehicle to design in which order i.e tyres inward.
The Mulsanne’s Corner includes a link to Le Mans Prototype design rules, which can give you and idea of dimensions and design ideas if you choose the track/race car option.
The Juno Racing and Formula SAE websites are to give you similar ideas.
Engineer to Win: The Essential Guide to Racing Car Materials Technology or How to Build Winners Which Don't Break by Carroll Smith
Tune to Win: The Art and Science of Race Car Development and Tuning by Carroll Smith
Drive to Win: The Essential Guide to Race Driving by Carroll Smith
Carroll Smith's Nuts, Bolts and Fasteners and Plumbing Handbook by Carroll Smith
Chassis Engineering/Chassis Design, Building & Tuning for High Performance Handling by Herb Adams
Competition Car Suspension: Design, Construction, Tuning by Allan Staniforth
Competition Car Data Logging – A practical handbook by Simon McBeath
How to Make Your Car Handle by Fred Puhn
Sheet Metal Handbook by Ron and Sue Fournier
Race Car Engineering & Mechanics by Paul Van Valkenburgh
How to Build and Modify Sportscar and Kit Car Suspension & Brakes for Road and Track by Des Hammill
Competition Car Preparation – A practical handbook by Simon Mcbeath
Performance Welding by Richard Finch
How to Run a Successful Race Team by Steve Smith
How to Blueprint & Build a 4-Cylinder Short Block for High-Performance by Des Hammill
Race and Rally Car Source Book by Allan Staniforth
How to Choose Camshafts & Time Them for Maximum Power by Des Hammill
Auto Math Handbook: Calculations, Formulas, Equations and Theory for Automotive Enthusiasts by John Lawlor
The Step-By-Step Guide to Engine Blueprinting: Practical Methods for Racing and Rebuilding by Rick Voegelin
Fiberglass & Composite Materials: An Enthusiast’s Guide to High Performance Non-Metallic Materials for Automotive Racing and Marine Use by Forbes Aird
Aerodynamics for Racing and Performance Cars by Forbes Aird
Race Car Aerodynamics: Designing for Speed by Joseph Katz
Low-Speed Aerodynamics by Joseph Katz and Allen Plotkin
Brake Systems: OEM & Racing Brake Technology by Mike Mavrigian and Larry W. Carley
Performance Wheels & Tyres: Tire Construction, Tire Construction, Tire Sizes, Alignment, High Performance Street & Racing Tires, Tire Testing & Tuning, Plus Sizing, Mounting, Balancing & Fasteners by Mike Mavrigian
Brake Handbook by Fred Puhn
The Car Builder’s Handbook: Tips and Techniques for Builders of Kit Cars and Street Rods by Doug McCleary
Fiberglass Repair and Construction Handbook by Jack Wiley
Race Car Chassis: Design and Construction by Forbes Aird
Race Car Vehicle Dynamics by William F. Milliken, Douglas L. Milliken
Fundamentals of Vehicle Dynamics by Thomas D. Gillespie
http://www.gmecca.com/byorc/index.html
http://www.mulsannescorner.com/
http://www.junoracing.co.uk/
http://www.sae-a.com.au/fsae/index.htm
Purchasing the books you need will cost close to if not over $1000. Race Car Vehicle Dynamics by William F. Milliken, Douglas L. Milliken I saw second hand for $208. Damn good book though but that’s an extreme case of price. Start with vehicle dynamics, chassis and suspension design books. By then you’ll know what area you need to know about next.
Don’t be thinking 18” rims and turbo conversions because bang for buck they’re not worth it even if you can afford them. And don’t think up crazy shit like mid-mount 4wd stuff because you won’t find a donor car.
Another option is to take an old car and restore it. Much Cheaper and still good fun to drive! My pick would be a Datsun 240Z, Ford Mk2 Escort or possibly something even as modern as a Peugeot 205 Gti. Whatever floats your boat but pick a car with good chassis design to start with, not Cadillacs and Yank stuff. The three cars mentioned will easily put paid to your Corolla.
I don’t think you would be able to build a car from scratch and have it on the road under $20000 but I may be wrong. $20000 = 89 GTR
Any other questions feel free to ask.