DJSR -01 : Weight - 248 kg’s

DJS Racing debuted in Formula Student Germany 2014 with its first prototype DJSR 01. With a group of 20 students and limited resources the team successfully managed to come up with a single cylinder open wheel racing car which was among the fastest teams to clear scrutineering. The team also placed 24th in the business event, making it 5th among the Indian teams overall, a remarkable feat for a debutant.[1] Due to minor technical glitches the team couldn’t compete in the dynamic events but learned a lot from the experience which paved the way for future advancements.

Chassis

AISI 1020 steel tubular space frame.
Tig welding with 1020 steel filler material.

Steering

Steering ratio 12:1. Carbon fiber steering wheel.

Engine

Royal Enfield 500 efi engine
Custom 3d printed intake. Aluminum fuel tank.

Electronics

Stock harness.

Suspension

Double unequal length arm.
Pull rod actuated horizontally oriented springs and damper, pull type actuated vertical.

Brakes

Wilwood GP310 Calipers.
220mm fixed rotors.

Transmission

Torsen differential.
Chain drive with unequal half shafts.

Composites

Glass fiber seat nose and side pods.

Achievements

Formula Student Germany 2014

24th in Business Presentation
61st in Cost Event
64th in Design Event
63rd position overall

DJSR -02 : Weight - 199.5 kg’s

DJSR 02 was built using a KTM Duke 390 engine, with the aim of reducing weight and thus boosting accelerating capability. The second prototype weighed just under 200 kilograms, achieving a 30% weight reduction over the previous variant. With this car the team competed at Formula Student India 2016 securing a 6th position overall despite being a first year team at the competition.[2] The all inclusive transmission and suspension design along with the compact packaging of the car lead the team to securing a coveted 4th position in the design finals. The team’s well maintained finances and budgeting resulted in the team placing 2nd in the cost event. DJSR 02 was among 9 teams who competed in the endurance event. The judges acclaimed the team’s design methodology and saw great potential in the team.

Chassis

Reduced the chassis length by 0.3 meters compared to previous car.
Compact packaging.
Optimum Wheel base and Track-width

Steering

Self-designed and manufactured rack and pinion assembly.
Carbon Fiber steering wheel.

Engine

Switched from Royal Enfield 500cc Classic Engine to KTM 390 Engine providing a better power to weight ratio and performance.
Introduced self-designed cooling system, exhaust assembly, fuel tank. 3-D printed intake using material Duraform black.

Electronics

Self-manufactured wiring harness.
Performance Electronics PE3 ECU.
Dash featuring RPM Indicator, gear indicator, fan switch, push start and kill switch.

Suspension

Use of light weight springs and dampers compared to previous car.
Reduced the rim size to 10 inches.
cal.

Brakes

Switched from Wilwood calipers in 01 to ISR calipers in 02.
Self-designed and light weight rotors.
Compact pedal-box with aluminum 6061 pedals

Transmission

Electronic Button shifter.
Light weight and compact assembly as compared to previous car.
Custom made clutch and throttle cable.

Composites

Use of Carbon Fiber for floorboards, triangulations, seat, sidepods.
Self-designed and manufactured nose made of glass fiber.
Use of accurately manufactured wooden moulds for precision manufacturing.

Achievements

Formula Student India 2016

2nd in the Cost Event
4th in design event
6th position Overall

DJSR -03 : Weight - 181 kg’s

DJSR 03’s first competition was Formula Bharat 2017 held in Coimbatore where team finished 6th overall. We were awarded 1st Prize in Design Event because of our excellent skills on validating the concepts behind designing the car. Along with this, team performed really well in static events and were 2nd best in Static events and 3rd most fuel efficient car at the competition.

The team even qualified for Formula Student Germany by being the 10th fastest team to clear the quiz all around the world. For this event, the car was upgraded after its Indian competition by implementing Drexler Differential, Data Acquisition System, Race Capture, etc. It was acclaimed the Best Indian team at the competition and was the 2nd best Asian team too. Team secured 41st position overall with 13th place in Design event, 16th place in Design event and 23rd place in Business Plan. Also, it was the sole Indian team to complete all Dynamic events.

Chassis

Steel tubular space frame chassis.
Laser cut tube profiling.
Compact design, lower center of gravity, light weight (25 kg’s)
Self-designed and optimized Carbon Fiber impact attenuator.
Efficient packaging and additional driver comfort.

Steering

Carbon fiber steering wheel
Carbon fiber steering column
Sparaco quick release
Reduced turning radius and increased cornering ability
Carbon fiber tie rods and toe rods
ABS 3D printed steering wheel grip

Engine

Water Cooled Rich Burn KTM Duke 390 Engine.
Displacement: 390cc
Engine Control Unit: PE3
Wet Sump Lubrication
3D Printed Intake Manifold
Custom resonated exhaust system.

Electronics

Custom programmable Performance Electronics PE3 ECU
Custom Wiring Harness
Electronic Solenoid Shifter with ignition interrupt
Data Acquisition System with telemetry.

Suspension

Double Unequal length A Arm
Push/Pull Rod actuation at front and rear
Penske Quarter Midget Dampers by Kaz Technologies.
Hoosier, R25B, 18 x 6 -10″ racing slicks, Keizer Aluminum RimsandAnti-roll bar.

Brakes

Self-made custom rotor
Adjustable pedal box
Ergonomic pedal design
ISR Brake calipers
AP Racing master cylinders
Al-6061 CNC machined Pedals
Goodridge brake adaptors and joints

Transmission

Power Transmission via Chain on Rear Axle
Sequential 6 Speed Transmission integrated in Engine Casing.
Clutch less Button Upshifting.
Clutch type limited slip Drexler differential.

Composites

Used vacuum bagging process for manufacturing complete carbon fiber bodyworks. Implemented self-designed and manufactured aerodynamic undertray.

Achievements

Formula Student Germany 2017

13th in the Cost event
16th in the Design event
19th in the Endurance Run
23rd in Business Presentation
41st position Overall

Formula Bharat 2017

1st in the Design Event
2nd in Static Events
3rd in Fuel Efficiency
6th in the Cost Event
11th in Business Presentation
6th position Overall

The team is redesigning most of their components to improve the car’s performance and is exploring upcoming materials and manufacturing techniques to optimize the overall construction of the car. The team plans to introduce ergonomically designed components, CF Undertray and much more and with extensive testing and driver training is sure of landing a podium finish in the competition this season.

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