Firewall
This was my first project as part of Cornell's Baja Racing team, focusing on designing the firewall for our off-road vehicle. The firewall is a critical component, acting as a barrier between the driver and the car's drivetrain, engine, and gas tank, ensuring safety during operation. It also provides structural support by connecting the car’s frame to the driver’s seat. As one of the largest parts of the frame, its design required precise alignment with other components and adherence to strict Baja SAE guidelines, making it an essential contribution to the vehicle's functionality and safety.
Design
The firewall design was driven by the need to ensure driver safety and structural support while meeting Baja SAE guidelines:
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Aluminum was chosen for its lightweight yet durable properties, adhering to the rule requiring a minimum thickness of 0.02 inches.
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The firewall was designed to align perfectly with the frame's geometry, with precise cutouts to accommodate frame members and maintain structural integrity.
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Efforts were made to keep the firewall as light as possible to enhance vehicle performance without compromising safety.
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The design incorporated filleted edges to facilitate laser cutting, ensuring accuracy and efficiency during fabrication, apart from basic safety during the manufacturing process.
Manufacturing
Starting with the CAD model, the design was transferred to an aluminum sheet, where dimensions were carefully marked, including an extra 1/4 to 1/8 inch margin to avoid overcutting. Straight edges were cut using a guillotine-like machine, while air tools were employed to create smooth, rounded cutouts for tube intersections. After fitting the firewall into the car and making necessary adjustments, the edges were grommeted to provide a polished finish and prevent scratches against the frame.
