FSAE IC Car Rebuild

Leading a team of passionate engineers to restore SDSU's last internal combustion FSAE car back to running condition. The project covers a full mechanical teardown and rebuild with proper documentation at every stage.

The engine — a 2003 Yamaha R6 — underwent a complete teardown, with critical components rebuilt using OEM or OEM+ parts and all torque-to-yield hardware replaced. An ultrasonic bath was used to clean carbon buildup from the piston head and remove gunk accumulated over 5 years of storage.

The chassis was surface prepped using naval jelly and sandblasting, then finished with an HVLP "candy" paint coating. Front and rear suspension were fully disassembled with proper documentation and parts tracked down for reassembly. Fabricated front and rear wing mounts for aero components to give the car greater tracking stability. Currently working on wiring harness selection to fit the available ECU and PMU.