Abstract
A vehicle chassis refers to the main support structure of the vehicle to which all components and automobile systems are attached. The chassis gives shape and rigidity to the vehicle and aids in supporting the various loads applied to the vehicle. Firstly, the detailed design and finite element analysis of a prototype go-cart for the eco-marathon challenge were documented. Secondly, Analytical method is used to calculate the shear forces (SF) and bending moment (BM) of the chassis and their corresponding SF and BM diagrams are provided. In addition, aluminum alloy profiles were objective selected over the conventional steel, because it’s lightweight coefficient which is significant for racing vehicle overall performance. The strength and durability of chassis are determined by engineering design principles. The vehicle was constructed from available local materials and welding as the major joining process. Finally, all other parts of the vehicle were attached to the chassis including the body and it was tested extensively for functionality and safety before going to compete at the Shell eco-marathon challenge. This work also delivers a cost-effective template for prototype vehicle chassis design for young engineers in the field of eco-marathon and motorsports in general that may have technology and facilities constrain.

Key words: Chassis design, Shell eco-marathon, prototype vehicle, energy efficient, FEA