Ethan Wood-Thomas | Mechanical Engineering

The 4WD system transmits torque from the rear gearbox to the front gearbox. Compared the use of a belt, chain, and propshaft - ultimately deciding on a belt due to its light weight, high efficiency, and ease of routing. Moved the driver sprocket to the intermediate shaft, reducing the front gearbox to a single reduction. Both sprockets were machined from 6061-T6 Aluminum with an anodized hardcoat to minimize wear. Removable flanges reduced installation time to 5 minutes. Custom Nylon idlers easily routed the belt under the engine and seat. These changes reduced the 4WD weight by 49%, reduced front gearbox weight by 35%, improved 4WD efficiency by 12%, and improved 4WD lifetime by over 800%.