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Old 03-23-2020, 09:22 AM   #21
S-N-R Customs
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Default Re: Club Car Electric Solid Front Axle

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I would love to have your skills, nice work.

Thanks for the kind words. I tell my students all the time. Just try... I’ve failed plenty of times, but you’ll never know what you’re capable of until you try. Then when the day comes and you get bogged down, just try to do something each day. Progress is progress no matter if it’s slow or not.


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Old 03-23-2020, 11:30 AM   #22
jakesnake27
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Default Re: Club Car Electric Solid Front Axle

Excellent work so far- following along
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Old 03-24-2020, 09:44 AM   #23
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Default Re: Club Car Electric Solid Front Axle


I was only able to get about an hour and a half in the shop this morning.... but I was able to make the axle extensions/u-joint mounts. You’re thinking axle extensions? Well I have 2” wheel spacers on the Jeep and I figured if I was cutting all this apart and redoing it... why not just widen the front end by 4”.
That piece of pipe you see is going to be turned on the outside to fit the axle tubes and bored on the inside to fit the new axle seals because I had to move them inward due to cutting the end of the axle tubes off.


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Old 03-25-2020, 05:13 PM   #24
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Default Re: Club Car Electric Solid Front Axle


I machined the oil-ite bushings today. (The inner axle is not in yet. I had to make the bushings so I could bolt it together and get the correct length) I’ll need to modify (or change) my hardware so my u-joints have a little more room.


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Old 03-25-2020, 05:23 PM   #25
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Default Re: Club Car Electric Solid Front Axle

Quote:
Originally Posted by S-N-R Customs View Post
I machined the oil-ite bushings today. (The inner axle is not in yet. I had to make the bushings so I could bolt it together and get the correct length) I’ll need to modify (or change) my hardware so my u-joints have a little more room.


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Ah, run it like it is. It might look real cool at night, with the sparks and all . . .

Really though , nice job. Looks well thought out! : X2
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Old 03-25-2020, 05:55 PM   #26
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Default Re: Club Car Electric Solid Front Axle



Wow! Great work and can't wait to see the final product.

Following.
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Old 03-26-2020, 09:20 AM   #27
Jkerle
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Default Re: Club Car Electric Solid Front Axle

Awesome project. It actually mimics the axle used by bad boy pretty closely. Have you looked at that axle at all? It may help/give you some ideas. I like your design as it is alot slimmer.

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Old 03-26-2020, 05:21 PM   #28
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Default Re: Club Car Electric Solid Front Axle


Today I did the final axle length and machined .015 off the shaft near the splines so the new axle seals have a place to ride.

The bad boy buggy axles are alright. When I say that I mean, they’re expensive and not designed to be easily rebuilt (I.E. “ball joints and C.V. Joints)

They actually modeled their axle off of the late 80’s Honda Fourtrax 350. I’ve never measured the bad boy axle. But I’m willing to bet it’s an exact match to the Honda.


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Old 03-27-2020, 04:31 PM   #29
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Default Re: Club Car Electric Solid Front Axle


Only spent a few minutes in the shop today. I disassembled everything and double checked the axle lengths before I welded them. Then I got a real head start on my “kingpins” (I’ll show how I made those tomorrow.)


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Old 03-29-2020, 03:09 PM   #30
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Here is how I built my kingpins. 1/2 stock with a shoulder turned to weld a 7/16-14 nut to the end and the other end is tapped for a 5/16-18 that a button head bolt and washer will attach to.


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