Brackets and mounts
SAE BAJA Front Steering Knuckle (Upright)
- Bounding box
- 164.0 × 130.1 × 206.0 mm
- Engine
- Precision B-rep
- Parameters
- 24
- Published
- November 4, 2026
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The prompt
Design a professional, manufacturing-ready Front Suspension Steering Knuckle (Upright) for an SAE BAJA / eBAJA off-road buggy. 1. Critical Design Requirements Use the following exact geometric parameters: - Caster angle: 4° - Kingpin inclination angle (KPI): 6° - Vertical distance between upper and lower A-arm mounting joints: 6 inches (152.4 mm). - Brake caliper mounting hole centre-to-centre distance: 89 mm (exact). 2. Main Components and Features Create a complete 3D CAD model incorporating: 1. Upper control arm mounting point with a suitable spherical bearing or rod-end connection. 2. Lower control arm mounting point with a suitable spherical bearing or rod-end connection. 3. Steering tie-rod mounting arm with a properly positioned tapered or machined mounting hole. 4. Brake caliper mounting bracket with two mounting holes spaced exactly 89 mm centre-to-centre. 5. Wheel hub and bearing housing integrated into the central body. 6. Wheel axle passage through the hub bearing housing. 7. Proper mounting provisions for the wheel hub assembly. 8. Reinforced structural ribs around the suspension mounting points. 9. Smooth transitions, rounded edges and fillets to reduce stress concentrations. 3. Geometric Design - Position the upper and lower suspension joints to achieve the specified 6° kingpin inclination. - Orient the steering axis to achieve 4° caster. - Maintain the specified 152.4 mm vertical separation between suspension joints. - Ensure the caliper mounting bracket is positioned relative to the brake disc and rotor clearance. - Keep the steering tie-rod mounting point geometrically compatible with the suspension steering system. - Ensure the hub axis, bearing seats and brake disc mounting arrangement are properly aligned. 4. Structural Design Design the knuckle for off-road eBAJA applications, considering: - High impact loads. - Suspension loads during jumps and rough terrain. - Braking torque. - Steering forces. - Fatigue resistance. - Minimum unnecessary material while maintaining structural strength. Use a practical manufacturable geometry with suitable machining access. 5. CAD Output Requirements - Generate a complete 3D solid model. - Use millimetres as the primary unit. - Create clearly defined mounting holes and bearing seats. - Keep the design symmetrical wherever mechanically appropriate. - Make the model suitable for further engineering modifications. - Provide an editable STEP file and native CAD format if supported. IMPORTANT: Do not change the four specified measurements. Treat them as fixed design constraints. Do not invent unspecified dimensions; use clearly identified preliminary dimensions that can be modified later.
Parameters
| Name | Value | Range |
|---|---|---|
| Caster Angle (GIVEN 4) | 4 deg | 0 – 12 |
| Kingpin Inclination (GIVEN 6) | 6 deg | 0 – 15 |
| Vertical Joint Separation (GIVEN 152.4) | 152.4 mm | 100 – 240 |
| Caliper Hole Spacing (GIVEN 89) | 89 mm | 60 – 140 |
| Caliper Hole X Offset | 50 mm | 25 – 70 |
| Caliper Bolt Hole Dia | 8 mm | 6 – 12 |
| Upright Web Thickness | 40 mm | 24 – 60 |
| Reinforcing Rib Thickness | 8 mm | 4 – 16 |
| Web Edge Fillet Radius | 5 mm | 1 – 12 |
| Hub / Bearing Housing OD | 88 mm | 70 – 120 |
| Hub Axis X Position | -5 mm | -30 – 20 |
| Hub Axis Height | 75 mm | 40 – 110 |
| Housing Inboard Face Y | -55 mm | -90 – -20 |
| Housing Outboard Face Y | 75 mm | 40 – 110 |
| Axle Passage Bore Dia | 40 mm | 25 – 55 |
| Bearing Seat Dia | 62 mm | 40 – 80 |
| Bearing Seat Depth | 24 mm | 10 – 40 |
| Lower Joint Boss Dia | 38 mm | 24 – 60 |
| Lower Rod-End Bolt Dia | 12 mm | 6 – 20 |
| Upper Joint Boss Dia | 32 mm | 20 – 50 |
| Upper Rod-End Bolt Dia | 10 mm | 5 – 18 |
| Steering Arm Thickness | 28 mm | 16 – 40 |
| Tie-Rod Boss Dia | 32 mm | 20 – 50 |
| Tie-Rod Taper Hole Dia | 10 mm | 6 – 18 |
Every value above is a live dimension. Open a model like this in the editor and each one becomes a slider you can drag before exporting.
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