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Reinforced Rail Design Needed

We used 1” aluminum square tubing for the rails design that supports the canopy and chassis. During the third test drive on grass (a bumpy surface), both rails broke, but not at the welds, so it doesn’t seem to be a fabrication issue—it looks like they were just overstressed. Switching to 1.5” aluminum tubing would be ideal since it’s almost three times stronger. For now, we're sticking with the 1” tubing and adding gussets on both sides of each rail to reinforce it. The final design will use 1.5” tubing.


 




Updated rail design - PDF and .dfx file

PDF

.dfx


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