Project Description

This project originated from a request by the NAU SAE Formula and Baja teams to design and build a custom toolbox cart that could meet the demands of their off-road competition environments and on-campus workshop activities. The cart was intended to solve several logistical problems the teams encountered:

• Difficulties transporting tools over gravel, grass, and uneven terrain during competitions.
• A lack of organized, lockable storage for tools, spare parts, and safety equipment.
• No built-in method to carry a fire extinguisher, which is required in pit areas.
• Limited access to power sources for charging devices or operating tools in remote settings.
• The need for a compact and ergonomic design that a single team member could operate efficiently.

To address these issues, our team applied core engineering principles to create a mobile, functional, and robust toolbox solution. The final product includes:

• A welded steel frame designed for durability and off-road use.
• 10-inch rugged casters for enhanced mobility across rough surfaces.
• Multiple lockable drawers and compartments to organize tools.
• A built-in mounting bracket for a fire extinguisher.
• An optional space for a portable power generator.
• Additional features such as a workbench surface, tire rack, and umbrella holder for shaded repairs.

This project provided an opportunity to integrate CAD design, FEA analysis, and real-world fabrication into a solution tailored to the specific needs of NAU’s SAE teams.