TM01 Cooling Controller

Overview

A waterproof, FSAE-grade enclosure designed to control the cooling loops on Terrier Motorsport’s TM01 racecar. The project involved fusing, connector selection, custom o-ring sealed housings, and waterjet steel mounting brackets.

Technologies Used

• CAD: Fusion 360
• Machines: 3D printer, laser cutter, waterjet
• Hardware: Deutsch connectors, tinyCWA pump controller, fan relay, fuses
• Materials: Carbon fiber, steel, cord stock, o-rings, acrylic

Key Features

• Fully waterproof enclosure with cord-stock seal
• Custom DT connector flange mounts with o-ring sealing
• Steel mounting bracket
• Accessible control panel

Contributions

I simulated the cooling loop using a high-voltage heater, configured pump and fan controllers, wired and fused the system, and fully designed and manufactured the enclosure.

Challenges

This project introduced multiple manufacturing constraints, including snap fits, compression seals, and multi-material assembly. It required extensive prototyping across several fabrication methods.

Developed during my first semester on Terrier Motorsport @ Boston University, February 2025

Other Photos

Inside of an early prototype

Custom DT connector flanges

Waterjet steel bracket