Homemade hubs for RWD independent suspension.

I have been working on these hubs for over a year. They are for a project that I started over 3 years ago right after I graduated high school. I got a Suzuki gs550 engine off of ebay and started building a go-kart frame around. 3 years later, I have learned so much that I realised that using hot rolled square tubing wasn't going to cut it. Currently, its all in limbo. Im trying to decide what I'm going to do with the mess I created over 3 years.

Hub. The main shaft is made form 8620 alloy steel. I want to have them case hardened so the seal doesn't wear out the shaft. the outer housing is a piece of unknown alloy steel that was about 2.25'' in diameter. I know from welding in a mis-drilled hole in another project that this alloy is hardenable. It cuts kind of like a grade 8 bolt. I made a custom boring bar to cut out the center to size. The bearing are just trailer bearings. The hub fits a standard metric ATV tire. I believe its a 115 mm bolt pattern. The driven side of the shaft has an adapter that goes form the 7/8'' shaft to the 1.25'' universal joints i have.

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Originally Posted by welderdude

Im trying to decide what I'm going to do with the mess I created over 3 years.

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I wouldn't call it a mess... looks like you've got some time invested there.. good job!

Hey thanks! I have put tons of time into it. It amazing what I have learned from taking on this kind of project.

I do know that I will have to re weld a lot of joints that aren't done correctly. When I made most of the cage, I only had a HF 90 amp mig and didn't know enough to use it to its fullest. I will probably invest in the rage 3 compound miter chop saw when I finally decide to start working on it again. Having to cut compound miter cuts with an angle grinder just sucks every bit of fun out of it.

Right now, I'm thinking about using what I already have and kind of rebuilding it into something even cooler. I just wish I had some real tubing and a tube bender, but that will come later when I have some money to throw around.

Wow, look at that double a-arm front suspension! I'll bet you have learned a lot working on this.

Have you looked at formula SAE racecars? They have some very cutting-edge designs, for a similar size vehicle and powerplant. They run on paved surfaces, not off-road.

A rear independent suspension, combined with adding triangulation to the frame, will open the door to tuning the suspension and making it handle more predictably, whether you intend to use this on paved or off-road application.

I checked out the formula SAE cars. That is pretty much what I had in mind when I started this project. I liked the idea of being able to run on concrete and then change springs and run on rough dirt. Now that I have thought things over, I think I'm going to try and finish what I have started.

your go cart must really fly with that engine in it!!!

I happened across this today and I'm asking myself "why haven't I started my project like this yet? You will have one hell of a fun toy when finished, no matter where you run it. As far as the heat treating for seal wear, ask yourself:"will I put enough miles on this thing to actually wear it out?" The reason I say is that typically in a situation such as this, you got a lot of more important things to worry about than whether a seal is going to wear a groove in 5,000 miles or 50,000 miles. If you see yourself getting 20,000 miles or more out of it, go for it. If not, don't sweat it, unless you just want to do it for a learning exercise. Either way, nice job!! Keep us posted.

Thanks hooda! I've decided that unless I acquire the proper heat treating equipment, I'll most likely end up screwing them up. They should be plenty strong the way they are now. If it ever becomes an issue, I'll redesign them and make it better.

On another note, taking on a project like this has given me new respect for engineers. Its amazing how much thought goes into each little part to make it work like it should.

Any thoughts for a roll cage? Or is it wide and low enough that it doesn't need one?

It has most of one now. Here are some fresh pictures of it. Its finally warm enough for me to start on it again.

Hey Dude, Any progress on this lately? The reason I ask is that I've been giving serious thought to starting a project to do a Harley-Powered Can-Am Spyder type setup (reverse trike). Only thing is that I've seen a few of these up close, and they're so well engineered, that I'm almost scared off the idea. I wouldn't want to invest a ton of design time into something that's not completely roadworthy.

Honestly, I really haven' done anything yet. Ill post some pictures later of the cluster I got my self into with a 93 jeep wrangler. Than darn jeep has kept me busy.

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Originally Posted by welderdude

Honestly, I really haven' done anything yet. Ill post some pictures later of the cluster I got my self into with a 93 jeep wrangler. Than darn jeep has kept me busy.

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Really cool pictures. It's a good project you've got there. In my opinion, definitely don't give up on what you've started. Have you figured out how the motor will be mounted?

Looking forward to what you are getting yourself into. If the cart is any indication, your Jeep working will be pretty interesting to hear about too! :)

The motor is mounted to the frame. I had a solid axle before and was able to drive around my dad's yard. It was pretty quick for how heavy it is. I am really tempted to scrap the current frame and get some real DOM tubing and follow the same design. I really like the flow of the frame. It has a mean stance. I will keep the same Indy/F1 style independent dual suspension.

Whats amazing is how I realised just how little I knew when I started this project over 3 years ago. I'm waiting until I have a garage I can keep it in. Having to work on it outside just kills my motivation and plus you never know what the weather will do here in illinois. If you dont like it, just wait a few hours, cause it will change :P

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Originally Posted by welderdude

The motor is mounted to the frame. I had a solid axle before and was able to drive around my dad's yard. It was pretty quick for how heavy it is. I am really tempted to scrap the current frame and get some real DOM tubing and follow the same design. I really like the flow of the frame. It has a mean stance. I will keep the same Indy/F1 style independent dual suspension.

Whats amazing is how I realised just how little I knew when I started this project over 3 years ago. I'm waiting until I have a garage I can keep it in. Having to work on it outside just kills my motivation and plus you never know what the weather will do here in illinois. If you dont like it, just wait a few hours, cause it will change :P

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Having to work outside is a pain. I'm in the same boat. Unfortunately, in the northwest, the weather isn't terribly accommodating. Pretty wet to be shooting electric arcs.

You made a good decision designing in the front suspension like you did. Every thought about changing the solid axle in the back? Would be more complicated but might make it worth your while.

Looks like it would make a good rat rod gocart!

Another option if you are concerned about seal wear, is to just use hub savers. They are a very thin hard stainless steel sleeve that presses on to the wear area. They are meant to repair hubs with deep seal grooves worn in them. Since you used standard trailer bearings, I'm sure you can find them. They also use the same type of system to repair harmonic balancers on engines with seal grooves worn in them. They are thin enough that you can use the same size seal, it will just have a little more tension on the slightly larger diameter shaft.

I would leave the square tube frame rails and cut off everything above the frame rails. Build you a round tube cage and let her eat! There's a lot of race car frames built from mild steel; if you build it right it will be safe. I would look into some type of external reverse transmission, like the ones used on heavy trikes or Honda Gold Wing. It will be a pain in the but getting out to push it backwards. It has a cool factor fo-sho!

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Originally Posted by Tacoma747

Looks like it would make a good rat rod gocart!

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I was thinking that as well.. lol

Thanks for posting pics!
I've been working on plans for a 2 seater buggy with a GSXR 1000 motor in it. I've got the motor but my big hold up is the hub for independant suspension in the rear. I need a disc brake on one side and a sprocket on the other...

I'm planning a mid sized sand rail with paddles. We have a riding area close that is all chat from the old lead mines, basically about double the grain size of sand.

This is not mine, just a sample of what I'm planning....
http://i33.photobucket.com/albums/d8..._buggy_002.jpg

Oh come on... Got to have something with some power to it... How about my toy??? I didn't make it... Just have had it for years. I have rebuilt it several times. Putting in rear seals right now... I broke the ring gear and snapped the axle... Some awesome wheelies... Straight pipe exhaust baby!!!!
Attachment 7104

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Originally Posted by Brian Ski

Oh come on... Got to have something with some power to it... How about my toy??? I didn't make it... Just have had it for years. I have rebuilt it several times. Putting in rear seals right now... I broke the ring gear and snapped the axle... Some awesome wheelies... Straight pipe exhaust baby!!!!
Attachment 7104

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That thing looks like it would do Great wheelies!!

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Originally Posted by CGCINC

That thing looks like it would do Great wheelies!!

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I had trouble with it hill climbing years ago. Just kept getting doggy under a load. After a lot of head scratching a buddy said maybe the coil is breaking down. Well instead of a new coil I went to a bone yard and pulled a whole electronic ignition. From the coil to the distributor the control module and wiring harness. Holy smoke... That baby will pull the wheels off the ground in 3 gears... No trouble at all climbing hills... Been having trouble caving in the oil pan even with the skid plate.