I ran through the to-do list for the front end and published it to the team today. I updated the list to reflect the changes to the CV support bracket from last week (welding no longer needed to fabricate this part).
Before I can call the CV bracket redesign complete, I ran the same static stress analysis that I ran previously. The new design’s safety factor dropped from mid-threes to 2.99. Officially out of the green zone, i.e. safety factor below 3.
Since the cutout only has to be wide enough to get the CV axle through it, I made the opening more square to increase the wall size at the top and bottom of the bracket. I also added another bolted-in cross-brace at the front of the bracket to increase lateral stiffness. The new safety factor came back 3.37. I think we can call the redesign done, now.
I also posted assembly and mechanical drawings for the front end to the to-do list. These should provide all the info to fabricate the front wheel suspension.
