Ryan ask for details on our steering system. We are running the most recent Blue Sky Design spindles which come with disc brakes and the ride height set for 16" wheels on our Blue Sky Design chassis.
We have extensively modified the vehicle. One of our design goals was to narrow the body work to reduce our frontal area (which will reduce aero drag and hopefully allow us to go further and faster with the same power).
We replaced the stock bent tubing steering handle with aluminum channel (1" by 1/2" and 1/8" thick).
We also use the same size channel to extend the steering part of the spindle so it is inside the body work when going straight.
You will notice the black bar that connects the two wheels together is mounted on a raised bracket attached to the original spindle. This was required on our car because we mounted our battery pack right where the shaft had been. The shaft now runs through holes drilled through the chassis.
This cleans up the air flow a little but adds opportunity for unwanted play in the steering.
Design challenges:
Steering handles need to be comfortable for driver. Position them with driver belted in and try full range of motion.
Leverage and range of motion change with spindle extension and steering handle length. Can the driver go from full right to full left and how much arm strength does it take when in motion? You need lock nuts on everything. The steering arms need to be tight enough not to flex. A little grease help where the steering arms rub on the chassis.
A simple steering lock means the steering can be set to straight for alignment and repeatability in measurements. In any vehicle all wheels need to be aligned to each other (left, right, front, rear) as well as the chassis. This is crucial for rolling resistance and handling. The angle aluminum holds the steering arms square to each other. They should be painted red to remind us to remove them before driving!
That Blueish bar that connects the spindles to the car, is that part of the frame or do you know of we can buy it by itself.
But thanks for all these pictures, it will help my team a lot.
The blueish bar is part of the one piece welded chassis.
it is steel rectangle 2" by 1" and probably 1/16" wall thickness. It needs to be strong since it carries most of the load transmiited through the front wheels.
it has 3" long 3/4" outside diameter and 3/8" inside diameter steel tubing to hold the bolt with copper " hats " top and bottom to actually locate the bolt. The angle of the tubing sets the wheel to zero camber.
