Switch-EV 25-26 AM Session

Rolling Chassis - Build 1 - Lower Bumper - Beam - Front Suspension (Install

Day 1

Inventory

List of Parts:

Beam
Beam Hardware
Bumper
Bumper Hardware
Trailing Arms
Thru Rods
Front Suspension Hardware
Upper Shock Mount Brackets
Shocks (w/ 200lb. coil over springs)
Brake calipers
Spindles

Beam Installation

The front right clamp being fitted to the Lower Beam and the frame

The front left clamp being tightened to the Lower Beam and the frame.

The finished installation of the Lower Beam to the frame

Day 2

Bumper Installation

Inventory of parts:

2 2" upper clamps
2 2" Lower clamps with center hole
8 bolts
8 nuts
Lower Bumper

Different angles of the bumper installation process

Bolt Photos

Clamp Photos

Floor Jack being set up to support the Bumper as we allign it and bolt it into place

Floor Jack in-use with a wood plank to give a larger surface area to support the beam during installation

Finished Bumper

Trailing Arm Installation

Trailing Arms and Thru Rods

Upper and Lower Trailing Arms inserted into the Beam

Thru Rods fastened to either end of Trailing Arms securing to Beam

Zirking

Action shot of Zikring the grease into the Beam tubes

The Greaser cap next to the Zirk used to lubricate the Trailing Arm

Day 3

oops

On Day 3, installing the suspension, we realized the bottom needed to attach to the trailing arm with an appendix. On Day 2, we had put the trailing arm on the wrong side and upside down. We had to remove the thru rod, swap the arms, and flip them for correct appendix alignment.

Realization kicking in that we messed up on the trailing arms

Taking out the Thru Rod to swap the Trailing Arms to Correct sides

Installing Suspension

Front Suspension being Fastened to the mounting panel on the frame

Front Suspension being fastened to the Lower Trailing Arm Appendix

Front Suspension being secured to Mounting panel from inside frame

Rear Suspension fastened to the frame and Swing Arm

Day 4

Brake Caliper and Spindle Assembly

Brake Caliper Alignment onto the Spindle

Fastening Brake Caliper to Spindle

Applying Thread Sealant

Realization of the task at hand kicks in

Application of thread sealant to brake caliper

Tightening the mouth of the brake fluid capsule

Spindle and trailing arm installation

View of bolt attachments for spindle to the trailing arms

Tightening of the bolts holding the spindle to the trailing arms

View of the completed brake and suspension system

Bumper/Beam Installation Presentation

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