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Old 03-21-2020, 05:48 PM   #1
S-N-R Customs
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Default Club Car Electric Solid Front Axle

I wasn’t going to post this until it was finished... but I have too many pics and need to clean some out. Anyway. I found the exact axle that I have in the mini Jeep and I’m modifying it into a steering axle. I’ll post a small write up and pic to go with it on each post.
At the moment...
I just have to machine the inner axles at the end to fit the U-joints and take about .030 off the shaft near the splines to fit the new oil seals.
Machine the “rings” to mount the new seals inward of the axle tubes.
Modify the bronze bushings that I’ll use as “ball joints”
Mount the steering arms.
And last but not least clean and assemble everything. When I do that I’ll mount the L&R backing plates on opposite sides so my brake cables face the back. Here is a pic of what I started with.


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Old 03-21-2020, 05:48 PM   #2
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Default Re: Club Car Electric Solid Front Axle


First thing was to disassemble.


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Old 03-21-2020, 05:49 PM   #3
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Default Re: Club Car Electric Solid Front Axle


Here is where all the work starts.


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Old 03-21-2020, 05:50 PM   #4
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Default Re: Club Car Electric Solid Front Axle


I cut the axle tubes at the ends where the welds are.


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Old 03-21-2020, 05:52 PM   #5
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Default Re: Club Car Electric Solid Front Axle


I used the chuck in my lathe to remove the axle tube that was inside the tube end. (Do not throw that away. It’ll be machined to hold the new bearing in the back side of the tube end)


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Old 03-21-2020, 05:53 PM   #6
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Default Re: Club Car Electric Solid Front Axle


Face the tube ends to square and match each other.


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Old 03-21-2020, 05:53 PM   #7
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Default Re: Club Car Electric Solid Front Axle


1st one done.


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Old 03-21-2020, 05:54 PM   #8
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Default Re: Club Car Electric Solid Front Axle


Rough cut the axles to length.


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Old 03-21-2020, 05:55 PM   #9
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Default Re: Club Car Electric Solid Front Axle


Cut the leaf spring brackets off.


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Old 03-21-2020, 05:56 PM   #10
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Default Re: Club Car Electric Solid Front Axle


There are those axle tube pieces that we saved from earlier, now machined to hold the rear bearing and the tube ends have had a snap ring groove machined to hold them in.


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