With nearly a decade of experience in racing and over eight years as a professional pit crew mechanic and fabricator, 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.

Recent Projects

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.

Rally Car Brake System (OEM Manufacturer)

Description

  • Led the complete design and integration of a high-performance brake system for a confidential OEM motorsports project.

  • 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

  • Delivered a fully functional, production-ready brake package that achieved professional motorsports braking performance within the tightest packaging constraints of any prior configuration for this platform.

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

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.

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.

Modular Roof Rack with Pneumatic Sunroof

Description

  • Conceptual roof rack system for the 5th Gen Toyota 4Runner, featuring perpendicular T-slot crossbars for versatile cargo mounting.

  • Integrated a pneumatic sunroof cover that can be opened and closed from inside the cabin, eliminating the need for external adjustment.

  • Engineered for structural durability under off-road vibration and loading conditions.

Development

  • Modeled the full assembly in Autodesk Inventor, applying parametric design and multi-body part modeling.

  • Incorporated supplier hardware CAD models to validate fitment, clearances, and attachment points.

  • Designed custom linkage and bracket systems with attention to DFMA principles (Design for Manufacturability and Assembly).

Results

  • Produced a detailed CAD concept demonstrating a unique aftermarket roof rack solution with an integrated, in-cabin sunroof cover.

  • Validated feasibility through digital modeling and simulation, ensuring proper fitment and motion without physical prototyping.

  • Highlighted potential improvements in user convenience and modularity compared to existing 4Runner roof racks.