With nearly a decade of experience in competitive motorsports as a driver, professional pit crew mechanic, and fabricator, Ben Baker combines real-world racing experience with mechanical engineering to design, develop, and improve high-performance vehicles and mechanical systems. His experience ranges from CAD design and manufacturing to race car development, telemetry, and vehicle dynamics, allowing him to approach engineering challenges with both analytical and hands-on perspectives.

Recent Projects

HRC Civic Type-R Rally Brake System

Description

  • Led the complete design and integration of a high-performance brake system for the HRC Honda Civic Type-R rally build for SEMA.

  • Tasked with fitting a full PFC caliper and rotor package into a severely constrained 15-inch wheel assembly, downsized from the stock 19-inch configuration while preserving braking performance and thermal capacity.

  • Took full ownership of the design and build process, coordinating manufacturing, validation, installation, and on-vehicle testing.

Development

  • Designed all caliper brackets, rotor hats, and clearance envelopes using Fusion 360 and SolidWorks, referencing OEM suspension schematics and integrating supplier-provided PFC CAD models that were modified for custom fitment.

  • Utilized 3D scanning of the hub and suspension assembly to ensure accurate packaging, and validated geometry through FDM 3D-printed prototypes before machining.

  • Created GD&T drawings for fabrication, managed supplier sourcing and cost optimization, and coordinated manufacturing of components at low cost without compromising quality.

  • Performed hydraulic calculations to select proper master cylinder sizes for optimal brake balance and pedal feel.

  • Assembled and validated the final brake system, collaborating directly with OEM engineers and aftermarket partners to confirm manufacturability and performance compliance.

Results

  • Designed one of the most compact brake packages developed for the FL5 Civic Type-R platform, integrating a full PFC motorsports braking system within a 15-inch rally wheel.

  • Improved manufacturability and serviceability through simplified bracket geometry, optimized tolerances, and consistent hardware interfaces.

Silent Communications Interface

Vehicle-Side

Crew-Side

App Function:

Description

  • Assistive communication system replacing radios with BLE-to-SMS messaging for racecar drivers who are deaf and hard-of-hearing.

  • Steering wheel–mounted 11-button input interface transmits preset messages; dashboard device displays incoming crew alerts in high-visibility text.

Development

  • Programmed in MIT App Inventor (BluetoothLE API) and Arduino IDE for the Adafruit ItsyBitsy nRF52840 (BLE 5.0).

  • Integrated embedded firmware, Li-ion power management, and BLE communication into a compact steering wheel module.

  • Designed button/electronics housing in Fusion 360, with 3D printing for prototyping and CNC machining for final fabrication.

  • Implemented a trusted-numbers system for secure filtering and a hardware interrupt (Dismiss button) for safe acknowledgement.

Results

  • Delivered the first HMI comms system for deaf drivers, bridging embedded hardware and mobile app development.

  • Improved reliability and fault tolerance over traditional radios through BLE-to-cellular integration.

  • Validated in on-track functional testing, demonstrating low latency, robustness, and ergonomic usability under racing conditions.

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 while improving durability, handling, and compliance for 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 in SolidWorks, lowering the upper control arm by 1.5 in to improve wheel clearance while maintaining suspension geometry.

  • 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 designed for repeatable manufacturing.

Racecar Intake Enclosure

Description

  • Pre-manifold intake system for a BMW E36 endurance racecar designed to increase airflow velocity and improve engine performance.

  • Targeted packaging constraints while maintaining structural durability under racing conditions.

Development

  • Used 3D scanning and Fusion 360 for CAD modeling within tight space limitations.

  • Performed CFD simulations (Autodesk CFD) to optimize airflow characteristics.

  • Validated designs with IAT and MAF sensor data, closing the loop between simulation and track performance.

Results

  • Increased intake velocity from 36 m/s (80mph) to 60.3 m/s (135 mph).

  • Contributed to back-to-back 1st-place podium finishes in endurance racing.

  • Demonstrated effective CAD-to-track workflow, integrating scanning, simulation, and real-world validation.