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Automotive

Pedal Box Assembly

Timeline
May 2025 - Present
Role
Ergonomics Lead | UT Longhorn Racing

Project Overview

Designed and manufactured an adjustable, lightweight, and reliable pedal box assembly optimized for rapid assembly and high-vibration racing environments.

Design & Analysis: Modeled the complete assembly in SolidWorks. Integrated dual master cylinders, a throttle return mechanism, and custom sensor enclosures. Validated the design by running FEA on the master cylinder mounting tabs, increasing material thickness to safely handle 200 lb input forces.

Manufacturing: Applied DfMA principles and GD&T to optimize for in-house post-machining and assembly. Primary components were waterjet-cut 6061-T6 aluminum, followed by manual machining (reaming precision holes) and aluminum welding for the pedal faces.

Integration: Secured safety-critical hardware for high-vibration environments using safety wire and flex-top locknuts. Integrated potentiometers for precise throttle and brake telemetry.

Technical Specifications

  • Primary Material:6061-T6 Aluminum (Waterjet & Machined)
  • Max Load:200 lbf input force (Validated via FEA)
  • Hardware Security:Safety wire and flex-top locknuts for high-vibration
  • Telemetry:Integrated rotary potentiometers for throttle/brake pedals
Pedal Box Assembly
Pedal Box Assembly Front View
01 / 10
Pedal Box Assembled
Pedal Box Assembled
02 / 10
Pedal Box Assembly
Pedal Box Assembly Rear View
03 / 10
Base Plate
Base Plate On the Frame
04 / 10
Partial Pedal Box
Pedal Box Partially Assembled
05 / 10
Pedal Arm Machining
Pedal Arm Machining Facing
06 / 10
Pedal Box R1
Pedal Box R1 My First Design
07 / 10
Pedal Arm
Pedal Arm Faced Down With Balance Bar
08 / 10
Pedal Box Parts
Pedal Box Parts Waterjet
09 / 10
Base Plate
Base Plate With Pocketing
10 / 10

Technical Skills Developed

SolidWorks Mill & Lathe DfMA Electromechanical Integration Vendor Outsourcing
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