Toe Bracket
The toe bracket is one of the crucial components of the suspension system. It constrains yaw of the rear wheels and allows toe angle adjustability. As -due to constraints of the suspension system and the chassis- we decided on adding a crossmember to our electric vehicle design, we had to come up with a somewhat unorthodox design for the toe bracket. Our main challenge was the designed toe link axis not being in line with the cross member. So the piece needed to contain hard-to-machine angles. This is why we couldn't come up with a simple CAM program, and had to machine manually. We first made an acrylic prototype, which informed us on design choices to make the piece easier to manufacture. After confirming material properties and failure scenarios in SolidWorks, we machined the toe brackets on Fryer CNC machines.
