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
First-of-its-kind driver communication system developed to provide real-time race communications for deaf and hard-of-hearing motorsports drivers.
Replaces voice radio with a steering-wheel-mounted wireless HMI and native Android application, allowing drivers to send structured messages while keeping both hands on the wheel.
Supports bidirectional team messaging, customizable decision trees, multilingual translation, and off-grid communication through Meshtastic.
Development
Designed the complete hardware and software architecture, including a custom 3D-scanned steering-wheel housing, ergonomic color-coded controls, embedded nRF52840 electronics, rechargeable power system, and BLE firmware.
Advanced the original MIT App Inventor prototype into a native Kotlin application using Jetpack Compose, MVVM architecture, persistent configuration storage, SMS/MMS messaging, Google ML Kit translation, and Meshtastic BLE integration.
Iteratively improved tactile feedback, button geometry, wire routing, interface visibility, and decision-tree navigation using driver and crew feedback from endurance-racing use.
Results
Delivered a functional, integrated communication platform that has supported Silent Racing’s deaf drivers during endurance events ranging from 7 to 24 hours.
Validated wireless connectivity, message transmission, group communication, saved configurations, translation functions, and multi-day controller operation, including more than 72 hours of continuous bench testing.
Demonstrated a scalable architecture with applications beyond motorsports in noisy, multilingual, and low-connectivity industrial environments.
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.
BMW M54B30 Race Intake System
Description
Designed a high-flow intake system for a BMW M54B30-powered E36 endurance racecar, replacing the conventional M50 intake conversion with a custom-adapted N54 intake manifold and sealed cold-air intake.
Unlike the commonly used M50 manifold conversion, the N54 manifold was selected for its shorter runner geometry and potential to improve high-RPM breathing while maintaining a broader, flatter torque curve. The system was further engineered to reduce intake-air temperature, improve engine-bay packaging, and withstand the demands of endurance racing.
Development
Utilized 3D scanning and Fusion 360 to reverse engineer the M54B30 cylinder head, M50 intake manifold, N54 intake manifold, and E36 engine bay, designing a custom adapter that aligned ports, injector geometry, bolt patterns, and sealing surfaces.
Performed first-principles airflow calculations, estimating a peak engine airflow demand of 0.214 kg/s at 7,000 RPM, using this analysis to guide throttle-body sizing and intake geometry while minimizing pressure losses and maintaining inlet velocity.
Reverse engineered the Eventuri Type-B filter housing, adapting its internal geometry to the available engine-bay space while creating a sealed cold-air enclosure optimized for manufacturability.
Produced iterative prototypes using PETG and ABS+ FDM printing, validating fitment, packaging, mounting features, and filter integration prior to final production.
Results
Successfully completed and fitment-tested a functional N54 manifold adapter and sealed intake enclosure, verifying engine-bay packaging, port alignment, and mechanical interfaces.
Reduced the overall intake package size while relocating the air filter outside the hot engine-bay airflow, providing a cleaner, cooler air source than the previous open-cone configuration.
Established a complete engineering workflow combining reverse engineering, CAD, airflow analysis, additive manufacturing, and physical validation, preparing the system for future chassis-dynamometer testing and ECU recalibration.
