Late nights, long days, and a rolling start can’t stop the UW Clean Snowmobile Team
For one week in March of every year, engineering design teams from universities of all over North America travel to Michigan Tech’s Keweenaw Research Center (KRC) in the northern city of Houghton, Michigan for the SAE Clean Snowmobile Challenge (CSC). For Waterloo, this was the opening year of their brand new snowmobile prototype: a 2012 Polaris RUSH Pro-R chassis and 750 cc turbo-charged four-stroke engine. Blood, sweat, and tears had been poured into this machine for the past year and hopes were high for team members Casey Palermo, Alec Espie, Vangie Rose, Chris Campbell, Thomas Forsythe, Dirk Friesen, and Kristen Sperduti as they set out to put their design to the test.
24 hours before departure required minor engine tuning and assembly, but unexpected problems with vacuum leaks, stale gas, drained batteries, and copious amounts of unburnt fuel being dumped into a very unhappy catalytic converter drove the team late into the night. At 4:15 a.m. on Sunday March 2, 2014, the Polaris was loaded into the trailer, running and ready to compete. The journey to Houghton later that morning was a quiet 16 hours, only to be disturbed by an eventful border crossing and multiple gas stops.
On Day 1 of the Clean Snowmobile Challenge, teams assemble at the KRC for technical inspection and unload their snowmobile and tools into the painted box area that will be their home for the rest of the week. After many hours in the frigid northern temperatures, the Waterloo snowmobile demanded thawing before firing up, but Waterloo passed technical inspection with minor modifications. Spirits were high for the week ahead!
Competition challenges begin on Day 2 with the Fuel Economy & Endurance Event, where each team’s snowmobiles convoy 100 miles from the KRC to Copper Harbor on the Michigan trail system. Chris Campbell was suited up for Waterloo to compete in the Endurance event, but during fuel-up of bio-isobutanol, they discovered fuel severely leaking from the fuel pump assembly retaining nut. Countless efforts were made to re-seat the gasket and nut, but time ran out. Research revealed that the part number was not registered at any Polaris dealerships; it was a part from Sweden and incompatible with the rest of the snowmobile chassis! Puzzled but determined to compete, Waterloo decided that anything can be fixed with two tubes of Seal-All and a strap wrench.
Waterloo’s Polaris snowmobile was outside and running by 8:00 a.m. on Day 3 to prepare for their 100 endurance make-up miles. Alec, Chris, and Thomas took the sled Out For a Rip on the designated handling track for pre-endurance testing, where a lesson was learned that the meaning of ‘snow’ cannot be fully understood until one visits northern Michigan in early March. Day 3 is also the Technical Design Presentations to judges and industry professionals.
Meanwhile back in Canada, remaining team members Casey, Dirk, and Kristen departed from Waterloo at 4:00 a.m. full of excitement in a race against time to be in Houghton by the late afternoon. Much to the surprise of their teammates, they showed up at the Copper Country Mall for the Static Display Event by 4:00 pm! The team finally fully assembled, they were ready to ride! Following the static event, more minor engine tuning was done to the Polaris at the KRC and it was tested and running smoothly by 12:00 a.m.
Waterloo entered the KRC on Day 4 to finally complete the endurance miles. They knew the sled was running great, so the team anticipated a smooth 100 miles would be under their belt in no time! Spirits were high until the key was turned in the ignition, and the sled remained silent; there was no electrical power whatsoever. Frustration set in as the sled was torn apart to diagnose the electrical system. It made no sense; the sled was running beautifully only hours ago! The discovery was made after an hour of analyzing – the positive battery terminal cable was completely split in half. With speed and precision, Alec Espie re-wired the cable and the sled roared to life!
Endurance miles were completed collectively by Chris, Casey, Dirk, and Kristen around KRC’s vehicle handling test track. There was a minor setback when the muffler needed slight re-attachment, but the miles were adding up quickly and the riders were having fun! With 85 of 100 laps completed, Waterloo watched their sled round an icy corner, slide sideways, and topple over. Luckily the rider was safe, but the sled required medical attention. Back to the KRC, the team un-bent the handle bars, re-attached the fire extinguisher, and re-secured the muffler. Northern Illinois University (NIU) graciously offered their kill switch and ignition switch, which required some wiring modifications, and had both been sacrificed in the crash. After long last, Waterloo completed their final victorious 15 endurance laps on the test track! And immediately after, they smoothly completed the In-Service Emissions Event right before the end of the day. That evening, as they recollected the events of the day, they couldn’t help but laugh at the luck that was handed to them. Despite so many setbacks, they were excited for the next day and ready to take on whatever challenges awaited.
Day 5 is the day that all teams fear: the AVL Lab Emissions Event, in which each snowmobile engine is pushed to its limit on a dynamometer (dyno) that runs through a 5-mode emissions test, beginning with Mode 1 at full throttle and full load for 121 seconds. Waterloo watched nervously as the previous team’s engine catastrophically failed, belonging to Michigan Technological University (MTU). Once Waterloo was hooked up, Mode 1 began. The engine was steadily roaring at 8000 RPM when suddenly it started making noises, described only by Alec Espie, “like popcorn on steroids.” The engine held steady and Waterloo held their breath. After 121 long seconds, the test was over! They survived!! After cheering and hugging and high-fiving, inspection of the snowmobile revealed a pile of silver chards and what remained of the aluminum muffler. It was split apart right down the center, and severed in half next to the flex pipe connected to the catalytic converter. From these charred aluminum remains, emerged the well-deserved name ‘Silver’, given to the first Waterloo snowmobile in years, to have survived the Lab Emissions Event, and made CSC history in its miraculous muffler explosion. The Waterloo team was shocked, happy and couldn’t stop smiling! Following the dyno event, the snowmobile was re-assembled. With the help of the University at Buffalo’s skilled welder, and some shopping at Autozone, a sufficient muffler was created.
Day 6 is the final day of CSC, and packed full of all the dynamic performance-related Events where the public is welcome to come watch! A weak and drained battery knocked Waterloo out of the running for the Cold Start Event, but they took the stage for the Acceleration Event where rider Kristen Sperduti put it to the bar and managed 71 mph in 500 feet, coming up just short to Idaho and Platteville (who tied with 73 mph) and finishing third place! Next was a race against time around the Objective Handling track where Waterloo placed a comfortable sixth.
At the Awards Banquet that evening, Waterloo was awarded the Aristo Intelligent Catalyst Technology Award for Most Improved Snowmobile, along with $1000 to boot! Despite the many setbacks during the week, the team pulled it together and made Waterloo Clean Snowmobile Team history, leaving Michigan with a strong platform and ready to build upon their success for 2015.
The UW Clean Snowmobile Team would like to give a special thanks to new-found team member, Malcolm Williams, for his contributions in times of need! As well, special thanks to the team’s faculty advisor, Professor Teertstra, the Dean of Engineering, the MME Department, the Sandford Fleming Foundation, WEEF, and EngSoc for their continued sponsorship, and thank you to all sponsors for their support. Thank you as well to the volunteers and organizers of the SAE Clean Snowmobile Challenge.
Check out sled.uwaterloo.ca or facebook.com/uwsled for more info!
Charlie
Awesome job!