Pedalbox
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July 2025 - present | Northwestern Formula Racing
Lead design of Northwestern Formula Racing's 2025-26 pedalbox - managing 100+ part Solidworks assembly through a transition to cut weight, simplify adjustability, and prevent prior issues with brake fluid leaks and ergonomic issues.
CAD
Previous Design
New Design
The previous design had various maintenance-related issues, including brake fluid leaks, wobbly pedals, and awkward bolt locations. I reconfigured the brake cylinders into an 'underslung' orientation, providing more favourable packaging, brake line routing, and fluid reservoir location. My design changes utilize a combination of metal and composite parts to reach an ergonomic, light-weight design that mounts into steel rails using easily accessible nylon patch bolts and welded nuts.
Full Assembly side view
Pedalbox 'Frame' Subassembly
All of our pedalbox components are mounted from a frame consisting of two flat 7075-T6 aluminum profiles, mounts for pedal shafts, and spacers. This is designed specifically to ease manufacturing while maintaing structural rigidity, optimizing load paths for forces upwards of 10kN.
Brake Pedal Subassembly
Accelerator Pedal Subassembly
FEA
10kN load case from master cylinders: 2.27 FoS
6kN reaction force case on brake pedal mounts: 4.17 FoS
12kN load case from brake pedal: 1.92 FoS
As per Formula SAE rules, the pedalbox should withstand a braking force of 2kN. Following a pedal ratio of 5:1, this resulted in a 10kN force we had to design the master cylinder mounting block around, as well as a 12kN reaction force at the pedal pivot (6kN on each pedal mount). The FEA cases above show how we simulated these forces on shaft mounts, master cylinder mounts, and the entire 'frame' of the pedalbox, clearing our design for manufacturing.
Manufacturing
Manufacturing to happen in Winter 2026. This will include CNC mill, waterjet, and lathe operations.
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