With nearly a decade of experience in racing and over eight years as a professional pit crew mechanic, Ben Baker brings a lifelong passion for vehicles to his engineering career. He combines hands-on motorsports expertise with a practical, design-focused approach to developing innovative and reliable engineering solutions.
Rally Truck Front Suspension
Description
Custom front suspension system for a rally-prepped 2006 Chevy Colorado, including uprights and aftermarket brake integration.
Built to increase suspension travel and track width with a focus on improved durability, handling, and compliance under demanding rally conditions.
Development
Utilized 3D scans of the frame and OEM upright as a foundation to design custom suspension arms and uprights.
Modeled suspension geometry using SolidWorks, lowering the upper control arm by 1.5 in to increase wheel clearance.
Created both metal and 3D-printed welding jigs to ensure symmetry and repeatability in manufacturing control arms.
Produced fabrication-ready parts using CNC plasma cutting and contributed to TIG welding during final assembly.
Completed all work under tight project deadlines while ensuring accuracy in packaging and fitment.
Results
Extended track width by +1.85 in per side (3.7 in total) for greater lateral stability.
Increased suspension travel from 3 in to 9 in, tripling wheel articulation and enabling the truck to handle jumps and rough terrain.
Delivered a fully integrated, competition-ready suspension and brake system that can easily be remanufactured.
Recent Projects
Racecar Intake Enclosure
Description
Bespoke intake pre-manifold intake system designed to accelerate the air intake velocity to improve engine performance for a BMW E36 endurance racecar
Development
Designed using 3D scanning and Fusion 360 for packaging limitations, tested using Autodesk CFD, and validated utilizing IAT and MAF sensor data
Results
Intake air velocity is accelerated from an averaged 80 mph to approximately 135 mph
Contributed to back-to-back 1st-place podiums in our endurance race series class
Description
Robust roof rack for the 5th Gen 4Runner, featuring perpendicular T-slot bars for versatile attachments
Incorporates an original sunroof cover that does not require the user to get out of the vehicle to operate it
Development
Used assembly features in Autodesk Inventor for design
Utilize dimension and CAD files from the hardware supplier to validate fitment and function
Results
The first aftermarket roof rack design to include a provision for sunroof protection that can be easily opened from within the cabin
Modular Roof Rack with Pneumatic Sunroof
Description
Developed an innovative communication system specifically designed for deaf racecar drivers, addressing the limitations of conventional radio systems in motorsports.
Engineered to utilize touch screen and hand controls (currently in development), integrated into the steering wheel for seamless communication, allowing drivers to send preset, group-based messages to the team.
Dashboard-mounted tablet displays critical messages from the team to the driver, providing real-time information without the need for auditory cues.
Example Decision Tree
“BROKEN”
BBCM Communications Interface
“WHEEL/TIRE”
Development
Employed MIT App Inventor for app design and functionality development.
Designed the steering wheel button mounting bracket using Autodesk Fusion.
The BBCM app runs continuously on a heavy-duty cellular device, mounted in the cockpit without obstructing the driver's view.
“SUSP/WHEEL”
“RF” (Right Front)
Results
Provides individuals who are hearing-impaired access to motorsports in ways previously unavailable, while remaining easy to use by anyone.
Delivers a solution that overcomes the limitations of traditional radio communication experienced in grassroots racing, such as distortion or lost connection.
Message sent to team:
”There’s an issue with the Right Front wheel/tire. Get a Right spare ready!”