Need Fab Advice - weld tabs?

slonomo

Hey everyone! I've never posted in this section before because I'm kinda a novice fabricator/wannabe fabricator, but I am venturing outside my comfort zone on this one and need some help.

I'm grafting an atv front suspension onto my G1 Yamaha and am not sure how to design the mounting tabs. I would really like to be able to "unbolt" the atv frame section just in case it gets damaged or whatever, am I just dreaming on this or is this a realistic goal? I know welding it in would be easier and quicker, and maybe stronger, but I'm just stuck on this idea.

So someone else suggested that I put 4 tabs on each side on top of the atv frame section, then mate them to corresponding tabs welded to the underside of the cart frame. The distance at the front is 0" and the distance at the rear is about 3". My quesions...

1. What material should I use for the "standoffs" and the tabs?

2. What locations should I use?

3. How many tabs would be safe?

4. Should these standoffs and tabs be gusseted?

My skills are decent for a beginner, but my welder is a flux cored unit and only has two settings. Should I also upgrade to a fully adjustable gas mig? or have someone do the final welds?

Here are some pics. Any advice would be greatly appreciated!











Thanks everyone!

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

DOOmsman

Slo, first thing check the angle of your spindles for the correct caster.
I would put the front tires on and block the rear wheels so the cart sits
on the suspension and is level, sorry if you have done this already.
a pair of tabs at the lower rear engine mounts and perhaps a square tube
cross brace at the front top.

slonomo

Thanks Doom, that's what I thought front mounts and rear mounts, but I didn't know if that would be strong enough. I guess the atv frame itself is plenty strong so as long as the front and rear mounting points are beefy and welded nice it should be strong enough, no?

Angle? Yeah I was researching that myself. Looking at photos doesn't cut it. I'll have to take the angle finder to a dealer and take a quick measurement off the bottom side of the frame on the straight part. I was thinking it was like 5 degrees, but in my photos that looks awfully steep doesn't it?

slonomo

Sorry I was meaning that my angle for the frame section of the atv was matched to the cart frame, and since it's on a jack in the front that puts it at 5 degrees up. So my intention there was to have the atv frame leveled to the cart frame, and it is in the photos, just not sure if that's the right angle. Once the cart sits down on the ground it will compress the front suspension so that it will level out more. I will most likely need to lift the rear another two inches or so to get it right. I can also play with the front shock mounting points to get the ride height in the middle of the suspension travel or slightly higher than leveled.

racin161

Slo first things first. Get the cart on 4 jack stands and level the cart front to rear and side to side. now you know the frame is flat or level. Make your mounting point for the rear part of your sub frame or front frame section. Tack or bolt it into position now you can move the frame section up or down to get it level which should give you the proper alinement ie caster-camber because it's already built in you frame section. You may also think about raising and lowering the front from factory specs as this will change the meant camber on your tires. Be sure to mock everything up and double check before final welding or bolting. Make sure everything is square and level find a measuring point on both sides of the frame and check diagonal to the lower ball joint. Hope this helps. Flux core wire is ok but nasty and in my old age I hate the smoke but double check all your welds ie clean and brush welds to see if there good.

shotgunbikes

Love the Subaru Brat seats! Looks like your off to a good start.

racin161

WELCOME TO BGW SHOTGUNBIKES

slonomo

Thanks for the advice, I actually just finished the final welds tonight. I did exactly as you said, leveled it, tacked it, mounted front then leveled subframe, etc. Worked great! It was definately a nasty process. I think I'll upgrade my welder to a mig gas unit. I have pics and will post them soon. Thanks again.

racin161

Great job SLO give us the pics!!!!

slonomo

Got some pics for you! It's on the ground, no steering yet. About 10" of lift over stock. Still have to address the rear.

Attached Images

	ATVSuspensionweldedsideview.jpg (194.9 KB, 17 views)
	ATVSuspensionweldedrear3.jpg (240.7 KB, 16 views)
	ATVSuspensionweldedrear2.jpg (232.7 KB, 15 views)
	ATVSuspensionweldedfront.jpg (194.0 KB, 17 views)
	ATVSuspensiononthegroundfront.jpg (181.4 KB, 19 views)