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Old 10-23-2012, 11:51 AM   #1
TCruz
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Default Finally a softer rear!

I have been complaining for a while now about the rear end of my cart treating my spine like it was an accordion! Been looking around for a long travel for the rear but so far all I could find was a kit but Stretch and one By Jake's. Both too expensive IMO so I decided to make my own.

Before I got started on the rear I wanted to get the front higher. I currently have a Jakes LT but was only able to get the shocks to fit in the 6" lift holes. Problem was the heims were running out of misalignment angle. If I wanted the shocks to be able to reach the 8" lift holes the tires were leaning way to the outside. So to fix this I found some high misaligned heims. Not spacers but heims themselves that offer up to 64 degrees of misalignment. Yeah, I can now lift the front to the 8"s. They are the QA1 1/2" high misaligned heims.

Before: Notice the shock is not connected on the bottom and the tire is off the ground. Shock lines up!



After: Shocks are all the way down to the highest lift!



Now for the rear: I looked and thought about using air shocks. I found some but they were for a truck and way too stiff. Looking in my shops attack I found my old stock Harley Davidson Ultra Classic shocks. These are coiled shocks with air assist. This solves the problem of the rear being too soft if I want to run my rear seat. Just add more air!

Now time to fit them in. I don't like to make permanent modifications so I wanted things to be removable if necessary. Only permanent mod is a half inch bolt welded to the top of the axle as a guide. I remembered seeing a setup that was not permanent and decided to build mine off of it. But to start I decided to build the top mounts and just tack weld a bracket to the bottom. I then just unhooked the rear of the leaf springs and went for a test.

The test went pretty well. I know the range of motion was going to be restricted by the short motion of the leafs but it was just a test!




Here is the front mount: The picture makes it look like the bar is welded to the frames but it isn't. The 1"x2" bar is welded to a 1/4" piece of angle iron that is bolted to the side rails. My step bars are covering them up at the angle I took the picture.


Rear mount from rear: If you'll notice the shock tower is held in place by the two u bolts and the bolt welded to the top of the axle. If I decide I want to use a different length shock of raise the cart, all I have to do I make a taller or shorter shock tower.




rear mount from the front: The front of the rear mount is also bolted to the plate that the brake cable runs through. This along with the welded bolt on top keeps the whole mess from wanting to spin around the axle.



Because of the angle my engine was sitting at, the air box was rubbing slightly on the gas tank. Since I lowered the front engine mount, I now have some room between the two.



Now it's riding as high as the Jakes LT will let it.



Took it out for a test run and man I am happy with the results! Now just have to take it all off again, gring it up some more, and paint it!
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Old 10-23-2012, 12:52 PM   #2
1moretoy
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Default Re: Finally a softer rear!

Very nicely done. Good looking welds too by the way.
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Old 10-23-2012, 04:11 PM   #3
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Default Re: Finally a softer rear!

This is the thread I was looking for!!!
I have the Jakes LT on the front too...and the rear is just way too stiff!
The rear is heavy duty leaf springs with the Jakes 2" blocks over the axles; this raised the rear of course....but its too stiff!
Im wondering if by adding longer shackles (say 6"-8") and maybe removing a few leafs from my heavy duty spring pack, i could ""soften"" up the ride?

PS..if this would work, I would get new rear shocks; like something adjustable/with reservior so I could set it stiff with passengers in back seat or set them soft for no passengers on the trails.

I'd be interested in your opionions on this idea?

Thanks in Advance!
j
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Old 10-23-2012, 06:07 PM   #4
TCruz
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Default Re: Finally a softer rear!

Before doing this I did the exact same thing. 6" longer shackles in the rear, 1/2" worth of spacers and removed 2 of the 4 leafs. The things liked to killed me. That was what I was running that made me do this. If you like I can send you a parts list and where I got my stuff and do what I did.
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Old 10-23-2012, 06:33 PM   #5
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Default Re: Finally a softer rear!

Nice. Great job figuring it all out. I'll be interested in seeing your parts list too. Any idea of the total cost your into on this?

One issue I have with my own cart is that the lift blocks over the spring & axle are in the way from allowing me to flip the Ausco disc brakes over so the lever is on top rather than down low picking up weeds & mud & whatever. Looking at your pics, it seems like you have loads of room to move the shock inward a bit if needed. Might have to improvise on the upper bracket a bit but still lots of room up there too.
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Old 10-23-2012, 09:08 PM   #6
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Default Re: Finally a softer rear!

Nice! Never would have thought.....

Ordering mine tonight off ebay!
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Old 10-23-2012, 09:41 PM   #7
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Default Re: Finally a softer rear!

Correct there AirJunky! I was looking at those brakes and noticed I would have to move them to inside a bit. Plenty of room to do so. Local fab shop is where I get my metal dirt cheap and most of the parts if not all were bought from speedwaymotors. Various nuts and bolts from Tractor supply up the road. Shocks I already had but you can finds loads of them eBay where people have swapped theirs out to low profiles. Shocks like mine can be found on Road Kings, Electra Glides, Ultras. Most on eBay don't have the air lines with them but O'Rilleys has screw in tank fill valves for 3 dollars. I wanted mine shocks adjustable separately anyway. All in all I have spent roughly a hundred fifty bucks.

I also had to get longer shift cables not included in the hundred fifty bucks for the rear suspension parts. I could have just drilled another hole lower in the body but didn't want to go that route.

For the arms:
1" ID round tube I think the OD on what I got was 1 1/2" pretty thick walled tube

On one end was 3/4" Four bar end Item #: 91008034 $13.99 each (need 2)

on the other end "SALE" Garage Sale - Pro-1 Series RH Male Heim, 3/4"-16 Shank/ 5/8" Hole Item #: 1750527GS $6.99 each (need 2)

WELD BUNG, 3/4"-16 RH THREAD Item #: 91002965 $9.99 (need 4)

3/4" Steel Jam Nuts - Pack of 6 Item #: 1756047 $3.99 (1 pack)

Steel Cone Spacers, 5/8" Hole Item #: 5464110 $7.99 (1 pack)


I had two different sizes of metal.
I had some 3/16 thick 2" wide flat stock long enough to make the upper mounts out of. The front bar that everything bolts to is out of 1"x2" x1/8" thick rectangular tube. That is welded to a piece of 2"x1/4" angle iron that is 7" long. One on each side. All the arm tabs and shocks tabs are from 2"wide x 1/4" thick flat stock. The lower shock plate is also 1/4" thick. I don't have the length of hand but it was long enough to cover the top of the ISO mount and when bend at a 90 degrees it rests against the brake bracket. I then welded a small piece at an angle to bolt it to that bracket. Motor mount was lowered by taking a 6"x6" x 1/4" plate and just lowering the factory mounting location down. Fab shop only charged me about 30 bucks for the metal and they bend the lower plates for me too. No way I could have bent that 1/4 plate neatly!

I like the Harley shocks, if I load up the rear with people or stuff I can add some air. Or let it all out for a super smooth ride!

The QA1 High misaligned heims for the front also came from speedyway. Only place I could find them.

If I can help anymore let me know. I was going crazy trying to fix my rear and spent a bunch of time trying to find parts that would work without breaking the bank.
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Old 10-24-2012, 05:29 AM   #8
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Default Re: Finally a softer rear!

Nice job TCruz, gave me some things to think about.
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Old 10-24-2012, 06:43 AM   #9
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Default Re: Finally a softer rear!

Very nice work man!

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Old 10-24-2012, 08:43 AM   #10
TCruz
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Default Re: Finally a softer rear!

Thanks for the encouragement guys! I did want to point out to others out there that would like to build a softer rear suspension but think they need some large, elaborate fab shop in order to do it; that it is not necessary. I did this with a chop saw, band saw (only one saw necessary), bench grinder, and a small 110 volt gasless welder!

Anything is possibly with determination! A tube bender would be nice though!!!! Honey if you’re reading this, Christmas is coming. Hint Hint!!!
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