Front Wheel Support

I bought more aluminum stock. I got heavier tubes for the front wheel support frames, with the thickness determined from the stress simulations I did previously. I also got some 3/4in flat bar for making CNC parts.

I redesigned the bracket that holds the CV axle to use the 3in x 5in square tube stock that I have. In the previous design, I hoped to fit the CV joint through the space inside the square tube, but the inside width of the square tube isn't wide enough.

Instead, I will cut a hole on the side wall that is big enough for the CV axle to fit through and mount the CV axle and brake calipers on the opposite wall. I think this design will simplify fabrication of the bracket. No welding is needed and there is less material compared to the last design.

I'm going to run the same stress analysis that I did for the tubes with this new layout and confirm structural integrity. If the simulations work well, I think we'll be ready to make these.