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Unread 05-21-2012, 11:19 PM   #1
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Default 3 Link rear in an Electric Cart

Anybody else fabbing there own?

If so let's see some pics (or links). I already did a search and came up empty handed

My Project:

1999 Club Car DS
Jakes IFS Long Travel w/18" Fox Shocks
3 Link rear w/20" Fox Shocks
25" 10x12 AT489's on Rockstar wheels
Santiago S10160 (hi torque) Motor
750 amp controller
1 gauge cables, upgraded F/R switch and Solenoid

I have the suspension set up at 10" lift and have 25" ground clearance to the frame. Still have the Panhard mounts to fab (bitch getting around the big motor). After the wreck I bought an early DS (fiberglass body 36V Resistor cart) and stripped it all the way down. So far I have the Jakes front end in, the trailing arms and mounts welded and the rear end in (sitting on jack stands with the wheels/tires on).

When this thing had the 8" lift and these 25" tires it would pull three horse slant (bumper pull) trailers around with ease and was pretty darn fast but it rode like hell so I am taking this opportunity to make it articulate better for hunting (I have a cool install coming for taking care of the hogs here)!
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Unread 05-28-2012, 04:09 PM   #2
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Default Re: 3 Link rear in an Electric Cart

Here are a couple of build pics..........





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Unread 05-28-2012, 04:13 PM   #3
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Default Re: 3 Link rear in an Electric Cart

I like it. I'm starting to draw up a 4 link for my G2 so this helps me out.
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Unread 05-28-2012, 09:15 PM   #4
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Default Re: 3 Link rear in an Electric Cart

I was able to finish tacking everything up today (I actually have about 6 days of work in this)! Making templates then brackets and fitting/reworking takes a lot of time.........





I got the Panhard bar and the "Third" link in and it all works well!





I still have to plate the bottom of this Panhard bar bracket, drill a few more holes, weld everyting up, completely, and then take it all apart to paint it..........

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Unread 05-31-2012, 04:39 AM   #5
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Default Re: 3 Link rear in an Electric Cart

Very nice work!
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Unread 06-24-2012, 07:11 PM   #6
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Default Re: 3 Link rear in an Electric Cart

Do you have the specs on the hardware you used, heim joints, bungs, tubing, etc?

Thanks
Rob
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Unread 06-24-2012, 10:43 PM   #7
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Default Re: 3 Link rear in an Electric Cart

I bought this stuff from ebay:

http://www.ebay.com/itm/390330636578...84.m1497.l2649
http://www.ebay.com/itm/390414013363...84.m1497.l2649
http://www.ebay.com/itm/390127265450...84.m1497.l2649
http://www.ebay.com/itm/370436718511...84.m1497.l2649
http://www.ebay.com/itm/370301642565...84.m1497.l2649

I made the trailing arms from 1.25" x .125" DOM (2qty 3" pieces cut to length) and used the bungs and 1/2 x 5/8 - 18 heim ends (2 pair).

The "third" link is made from the same......(another pair of heims and bungs and 1.25 od x .125 DOM)

The Panhard bar is made from .065" x 1" DOM and the 7/16 x 7/16 heims and bungs.

Hope this helps!
Gary
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Unread 06-28-2012, 09:15 PM   #8
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Default Re: 3 Link rear in an Electric Cart

Excellent information, Thanks

What did you use for material thicknesses for the different brackets?

Thanks
Rob
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Unread 06-28-2012, 10:09 PM   #9
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Default Re: 3 Link rear in an Electric Cart

Rob

I used 1/4" plate where ever the brackets were doubled (like the shock brackets on the rear end). I used heavier plate in places where appropriate but keep in mind I was reinforcing an aluminum frame.

The "strut" (curved bracket around motor) which locates the rear end of the top link was made from 3/8" plate and while thick enough (the force is actually against the edge), I only used two rear end bolts to attach it to the axle tube (axle to third member bolts). This was a mistake as it worked itself loose, repeatedly, so I welded it to the axle flange. Not really a big deal as the other brackets were welded on also........

You will need to brace the crap out of the bracket at the other (top) end of the third link as there is a TON of force there. Think triangulation......

The panhard bar mounts also take a lot of force so triangulate them also.
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Unread 06-28-2012, 10:44 PM   #10
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Default Re: 3 Link rear in an Electric Cart

I just perused my pics and see that I still had a single mount for the rear shock in these posted pictures. I changed shocks to a "eye to eye" style as one shock broke (I think it was sold to me bad from ebay) so I changed the mounts to work (dual tabs instead of the single shown). Either would work and if you want ONE Fox podium like in these pics I'll sell it, you can buy another single on ebay to match........

Gary
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