2018 Camper Van Project
Objectives:
Transform a Ford Transit T250 high-roof van into a functional camper optimized for race weekends involving bicycles and motorcycles. Outside appearance to remain as close to stock and stealthy as possible to deter theft.
Design Requirements:
Must accommodate 2 dirt bikes and provide sleeping arrangements with a fold-down bed.
Construction utilizing steel tube for durability and security, attaching structures directly to the van's body at existing hard points.
Comprehensive insulation with 3M Thinsulate, and interior design featuring vegan leather, recycled wool felt, and a woven textile headliner.
Incorporation of an L-track system for flexible and secure modular mounting.
Functionality:
Designed to serve as a mobile home base for racing events, with a focus on storage flexibility, thermal comfort, and interior aesthetics.
2024 Camper Van Rebuild (in progress)
Objectives:
The use case for the van has changed as motorcycle racing is no longer one of the driving factors. A complete overhaul of the camper van to support the exclusive use for mountain biking, with a focus on integrating permanent living solutions and secure bike storage.
Design Requirements:
Integration of a permanent queen-size bed without compromising internal bike storage capacity.
Power system sized to live completely off grid for 3 days without compromising comfort
Space for 4 mountain bikes on a pull out drawer for easy access and good ergonomics
Storage for gear and all living necessities
Comfort of home away from home, so we can be rested and ready to race
Bathroom
Functionality:
Bed upgrade to natural latex mattress, cut to size and fit perfectly into the space availabe, and the addition of Froli bed springs to achieve the feel of a full mattress and box spring within 8 inches of Z stack.
The rebuild focuses on enhanced living and storage capabilities for mountain biking enthusiasts, integrating high-tech solutions for energy efficiency, automation, and comfort.
Upgrade of the power system with advanced components including 7.2kWh LiFePO4 batteries, a 3kW inverter, 600W solar panels, and floor heating.
Utilization of ESP32 microcontrollers in a mesh network for centralized control over lights, heaters, water system, inverter, charging, battery monitoring, vents, and fans.
Harnessing 3D Printing for Practical Innovations
My enthusiasm for 3D printing stems from its remarkable capability to offer practical solutions to daily challenges. 3D scanning, modeling, and printing in a variety of materials equips any engineer with an unparalleled resource for innovation. This process not only accelerates the iteration cycle but also provides a hands-on opportunity to master the nuances of 3D printing, despite its limitations, and leverage them to achieve practical outcomes.
Furniture Design
In the realm of home design, the fusion of aesthetic appeal with practical functionality represents the pinnacle of craftsmanship. My journey into furniture design embodies this philosophy, resulting in the creation of three custom pieces that not only enhance the living space but also reflect a meticulous attention to detail. Each piece, conceived and built for our home, stands as a testament to the potential of combining traditional design principles with modern innovation.
Upon entering our home, guests are greeted by a striking console, a sophisticated piece that redefines the entryway. Tig welded from steel and adorned with two glass shelves, it serves as a solution for storing keys and other daily essentials. Its sleek design and transparent elements create a sense of openness and light, welcoming all who step through the door.
The heart of the home, our kitchen, is anchored by a custom-designed island that is both a culinary workstation and a storage solution. Specifically tailored to house a microwave and other kitchen appliances, this island optimizes space without sacrificing style. Elevating its visual and textural allure, the inclusion of floating shelves introduces an engaging layer of complexity to the piece, inviting both utility and a dynamic visual interest.
The centerpiece of our living room, this coffee table marries the industrial strength of stainless steel with the comfort of a soft top. Designed to be both a focal point and a functional piece, it offers a unique visual contrast and tactile experience. The choice of materials reflects a preference for durability and style, ensuring that the table can withstand the rigors of daily use while maintaining its elegance.
Exotic Hardwood Settlers of Catan game board
My friends and I are obsessed with Settlers of Catan. I've crafted a bespoke game board utilizing exotic hardwood to bring a touch of elegance to every game night. This unique creation stands out not just for its aesthetic appeal but for the innovative use of 240 hidden magnets embedded within all the pieces. These magnets ensure that each hexagonal piece can connect in any orientation with another, facilitating effortless self-assembly. Furthermore, the numbered tokens are designed to self-center, thanks to the magnetic alignment, enhancing the tactile experience and ensuring seamless gameplay. This board is a testament to the marriage of form and function, offering an unparalleled Settlers of Catan experience.
My lifelong passion for bicycles began with the simple joy of riding around the neighborhood, balancing on curbs, and launching off retaining walls with friends. This early love evolved into a deeper involvement with the cycling community through riding and racing bikes. Eventually, my interests broadened to include mountain biking and dirt jumping, further diversifying my experiences and skills on two wheels. My commitment to the sport expanded as I volunteered to build bike trails, fostering environments where others could enjoy and share in the thrill of biking. This journey, marked by a progression from casual rides to more structured forms of cycling, reflects a dedication not just to the activity itself, but to the broader culture and community that biking fosters.
Motorcycles: A Journey Through Custom Builds, Racing, and Design
My passion for all things with two wheels spans the building of custom café racers, the adrenaline of racing supermoto and dirt bikes, designing motorcycle parts for show and function while furthering my understanding and innovating within the realm of motorcycle dynamics.
Engineering Precision: Designing Motorcycle Parts
Our journey also delves into the meticulous process of designing motorcycle parts. Utilizing advanced tools like Tony Foale’s Motorcycle Setup Analysis Software, Kinematic and Motion dynamic simulations, and Finite Element Analysis (FEA) for strength and stiffness, This analytical approach ensures that every modification and custom part isn't just a guess but a calculated enhancement to the machine's performance and rider's experience.
Custom Café Racers: The RD 350 Project
The RD 350 project encapsulates the goal of creating a quick, light, and exhilarating canyon carving machine. This endeavor serves as a design study in motorcycle dynamics, employing geometry and linkages to refine handling characteristics. Key objectives include centralizing mass, decoupling systems to separate bump and brake dive, and optimizing for corner exit speed on tight, twisty roads. The project prioritizes hands-on building and learning, with a suspension system designed for a 30% change in effective spring rate without affecting trim and ride height. Mechanical front-end anti-dive setup, inspired by '70s race bikes, and an array of high-tech components underscore a commitment to precision and performance.
Collaborative Ventures: XR 650 "Cabin Fever"
In collaboration with Daniel Peter for his Honda XR650 "Cabin Fever," this project highlights the communal spirit of the motorcycle building community. My contribution focuses on the customization of the subframe, demonstrating the blend of technical prowess and creative vision that characterizes our approach to motorcycle design. This motorcycle was featured on BikeExif.
Racing Spirit: Supermoto and Dirt Bike Racing
The thrill of racing supermoto and dirt bikes represents the dynamic aspect of our motorcycle passion. It's where the rubber meets the road, and the theoretical aspects of motorcycle dynamics are put to the ultimate test. Racing not only fuels our competitive spirit but also provides invaluable insights into the practical application of our custom designs and modifications.
This blend of projects and interests showcases a holistic engagement with the world of motorcycles, from the workshop to the racetrack, underpinned by a relentless pursuit of innovation, performance, and a deeper understanding of motorcycle dynamics.
Empowering Mobility: My senior design project
Jake, an 11-year-old boy with a simple wish for mobility, faced challenges that made riding a traditional bicycle impossible due to his physical limitations. This crucial need led to a senior design project that not only sought to fulfill Jake's desire but also to overcome the hurdles that previous attempts had failed to surmount. With my background in bicycles and a keen understanding of the intricacies involved in custom bike design, I embraced the challenge as an opportunity to make a significant difference. Leading a dedicated team of six, we set our sights on creating a trike that was not only safe and easy to operate but also adaptable to grow with Jake.
Our objectives were clear: prioritize rider safety, optimize gearing for effortless operation, ensure the trike was simple for Jake to use, and adhere to a strict budget. The project, marked by previous unsuccessful attempts, demanded a fresh perspective and a commitment to innovative problem-solving. Teaming up with Easterseals, we embarked on a journey of design and engineering, driven by compassion and the resolve to succeed where others had not.
The result was a custom-built trike that transcended the mere functionality of mobility; it was a vessel of freedom for Jake, tailored to his unique needs and ready to evolve with him.
Awards: 1st place at Senior Design Expo
I embarked on a project to construct a 3 DOF (Three Degrees of Freedom) racing simulator, starting with a base DOFreality motion platform. Through meticulous reinforcement, reworking, and the addition of essential features, I transformed it into both a competent training tool for serious racing preparation and an enjoyable toy for off-season leisure. After fully immersing myself in this endeavor and reaping its benefits, my interests led me to explore new hobbies. Consequently, I passed on the torch by selling the entire platform to a race team. It continues to serve its purpose admirably, aiding drivers in learning new tracks and honing their skills.
Formula SAE® is a student design competition organized by SAE International (formerly Society of Automotive Engineers).
2011-2012
UIC FSAE Autocross
CNC table designed and built with the intention of expanding capabilities. 3 axis control allows intricate 3D milling operations.
Timeline:
• Research and planning: 3 months
• Build: 3 months
• Testing and tuning: 1 month
• Total: 7 months
Features:
• Spoil board, and attached frame, slide off to reveal a water tub with slats for plasma cutting.
• Windows PC, CNC electronics, packaged into single tower case.
• A large cooling fan at the front forcing air through a filter cools the motor drivers. Positive pressure inside the case keeps dust out.
• THC (Torch height controller) automatically controls plasma cut parameters.
2013 - completed
Objectives:
• tight packaging
• light weight
• fit to my dimensions
2014 - completed
My wife and I share a profound passion for giving neglected dogs a second chance at life. Through our dedicated efforts in fostering, we have successfully rehabilitated over 60 dogs, preparing them for their forever homes. This journey has not only been about saving lives but also about enriching our own, especially when we experienced a "foster fail" and adopted Cooper, a testament to the deep bonds formed during the fostering process. Each dog we foster is a step towards healing and hope, reflecting our commitment to transforming the lives of these animals, one paw at a time.
(presented here are just a few of the 5000+ dog photos on my phone)
