Machining for SR26 and SR27

CWRU Motorsports (Baja SAE), manufacturing engineer · Aug 2025 to present

Most of my time on the team is spent in the shop. I've machined more than 15 unique parts for the SR26 car and the SR27 build, out of 6061 and 7075 aluminum, 4130 and 4140 steel, Delrin and UHMW.

A finished SR27 yoke in 7075 aluminum. — A finished SR27 yoke.

The same yoke from the side, showing the ears and cross holes. — The same yoke from the side.

A yoke partway through machining, still attached to its stock. — A yoke partway through, still attached to its stock.

What I did

Turned spacers, bushings, and steering and shifter inserts on the lathe, holding ±0.001 in on the press-fit bores.
Programmed multi-setup 3-axis toolpaths in Fusion CAM for the flyweight fixtures, then ran the CNC jobs for the flyweights and the torque limiter hubs.
Machined the SR27 front inboard yokes on the 4th axis.
Milled weld-jig fixture blocks and notched frame tubes so the frame could be welded in a fixed jig, and waterjet-cut more than ten steel mounting tabs that were welded onto it.

Most jobs start from a team shop drawing like this one, for a rear upright fixture in 6061.

Result

My parts ran on SR26 at competition, and the SR27 yokes are going into next year's car.

Next project: Pre-Competition Drivetrain Teardown →