I posted this on another thread regarding pre-season preperation. This may be helpful here, too. Vanden Robotics actually has two classes. Manufacturing Technology for the rookies (VEX oriented), and Principles of Engineering for rookies and experienced students (FRC oriented). We also have AP Computer Science, whose prerequisite class is Principles of Engineering.
This is the handbook for the Principles of Engineering class. It may give you some ideas for running a class and not just a club.
http://www.vandenrobotics.com/#!handbook/cra3