Abstract: An apparatus and methods are provided for a modular front drivetrain comprising a single assembly that may be installed onto and removed from a vehicle. The modular front drivetrain comprises a modular chassis supporting a transaxle, a front differential, and a steering gear for operating front wheels of the vehicle. The transaxle, the front differential and drive axles convey torque from an engine onboard the vehicle to the front wheels. A spindle assembly is coupled with each front wheel of the vehicle and pivotally joined with the modular chassis by way of a front suspension system. Steering rods coupled with the spindle assemblies horizontally rotate the front wheels according to operation of a steering wheel onboard the vehicle. The modular front drivetrain advantageously facilitates replacing an entire drivetrain and suspension assembly quickly and easily in the event of a part failure during racing applications.

Abstract: A modular chassis is provided for an off-road vehicle to improve assembly, servicing, and repairing of a drivetrain of the off-road vehicle. The modular chassis includes a chassis to support components of the off-road vehicle. A front frame module couples with a front of the chassis, and a rear frame module couples with a rear of the chassis. The front frame module supports lower suspension arms of the off-road vehicle by way of inboard bushing joints. The front frame module supports at least a steering gear and a front differential of the off-road vehicle. The rear frame module is a tube-frame structure that supports components of the off-road vehicle. A lower portion of the rear frame module extends rearward and acutely upward to a top frame member that couples with upper side portions of the chassis. Several cross-members impart structural integrity to the rear frame module.

Abstract: An apparatus and methods are provided for a chassis for an off-road vehicle that includes a roll cage chassis spine. The chassis is a welded-tube variety of chassis that includes a front portion and a rear portion that are joined to an intervening passenger cabin portion. The roll cage chassis spine includes a front canopy and a rear canopy comprising an overhead spine to the chassis that increases the strength of the chassis and improves the safety of occupants within the vehicle. The rear canopy couples to the rear portion of the chassis, and the front canopy couples to the front portion of the chassis and the rear canopy. The front canopy and the rear canopy are configured to cooperatively reinforce the chassis during loading forces on the front portion due to front struts and loading forces on the rear portion due to rear struts.

Abstract: A suspension is provided for coupling a front wheel with a chassis of an off-road vehicle. The suspension comprises upper and lower suspension arms that each includes two inboard mounting points to the chassis and one outboard rod-end joint to a spindle assembly coupled with the front wheel. A ball comprising each outboard rod-end joint is fastened by way a bolt between a pair of parallel prongs extending from the spindle assembly. The upper suspension arm is configured to facilitate coupling a strut between the lower suspension arm and the chassis. A steering rod is coupled with the spindle assembly by way of a steering rod-end joint that is disposed forward of a drive axle, thereby decreasing leverage of the front wheel on the steering rod and substantially eliminating bump steer that may occur due to rough terrain.

Abstract: A window net door attachment is provided for coupling with a vehicle door to provide protection to occupants within the vehicle during travel over rough terrain or during rolling over of the vehicle. Framed portions of the window net door attachment surround an open area between a top of the vehicle door, a roof, and a windshield area of the vehicle. A window net within a boundary support is attached to the frame portions and to the top of the vehicle door, such that the window net is disposed throughout the open area. Attachments along the boundary support retain the window net in an extended disposition within the open area. Vertical supports may be interwoven with the window net so as to impart relatively greater strength to the window net.

Abstract: A vented roof panel is provided for an overhead portion of a roll-over protection system of an off-road vehicle. The vented roof panel comprises a planar member that includes a shape and a curvature that match the overhead portion to enable closely attaching the vented roof panel to the roll-over protection system. The planar member is formed of any of various plastics, such as injection molded plastic, or other similar materials. An air scoop including an air inlet port is centrally disposed in the planar member. The air inlet port is disposed in a forward-facing portion of the air scoop and configured to direct an airstream from outside to underneath the vented roof panel. The vented roof panel may be attached to tubular frame members comprising the roll-over protection system by way of one or more suitable fasteners.

Abstract: An apparatus and methods are provided for a transmission for a rear mid-engine vehicle. The transmission comprises a power transfer portion for receiving torque from the engine and a gearbox for providing conversions of rotational speed and torque. First and second side output portions conduct torque from the gearbox to the rear wheels. A forward output portion conducts torque to front wheels of a four-wheel drive vehicle. An air clutch comprising each output portion controls the degree of torque transferred to each wheel. The output portions are each coupled to a rear wheel by a rear axle, bevel gears, and rear portal gears. The rear axles are aligned with, and positioned above, the trailing arms to protect the rear axles from damage due to rocks and debris. The length and alignment of the rear axles cause CV joints to articulate in the same direction as the trailing arms.

Abstract: A universal axle-hub assembly is provided for an off-road vehicle. The universal axle-hub assembly comprises a wheel hub that receives a constant velocity (CV) axle snout into an opening extending through an axle support of the wheel hub. An outboard-most portion of the opening is a splined portion that engages with similar splines disposed on an outboard-most portion of the CV axle snout. An inboard-most portion of the opening is a smooth portion that receives a smooth portion of the CV axle snout. The axle support extends through an entirety of the width of a bearing that supports the wheel hub, such that the bearing supports the smooth portion of the CV axle snout and substantially eliminates shear forces acting on the splined portion of the CV axle snout. A bearing carrier supports the bearing and may be fastened onto a trailing arm or a spindle of the off-road vehicle.

Abstract: An apparatus and methods for the lubrication of the engine of an off-road vehicle, such as when the vehicle is airborne or upside down due to tipping over. The apparatus includes an upper chamber and a lower chamber. Fluid communication is established between the upper chamber and the lower chamber by way of a central tube. One or more vanes are arranged in the interior of the central tube to inhibit oil flow from the lower chamber to the upper chamber when the vehicle is upside down. An inlet hose connector is configured for receiving engine oil from an oil cooler and supplying the engine oil to the lower chamber. An outlet hose connector is configured for conducting the engine oil from the lower chamber to the engine. A bypass hose connector is configured for allowing the engine oil to exit from the upper chamber to the engine.

Abstract: A low suspension arm strut coupling is provided for a suspension of an off-road vehicle. The suspension comprises a lower suspension arm that is hingedly coupled between a chassis of the off-road vehicle and a spindle assembly that is coupled with a front wheel. An upper suspension arm is hingedly coupled between the chassis and the spindle assembly. A strut is coupled between the lower suspension arm and the chassis. A lower pivot couples the strut to the lower suspension, and an upper pivot couples the strut to the chassis. The upper and lower pivots provide a lower center of gravity of the off-road vehicle and a relatively smaller shock angle. The lower suspension arm is reinforced to withstand forces due to movement of the front wheel and operation of the strut in response to travel over terrain.

Abstract: Embodiments relate to an off-road vehicle comprising a frame, including at least one cargo box support member, a suspension movably coupled to the frame, a passenger compartment, an engine, a transmission operatively coupled to the engine, and a cargo box. The cargo box includes a floor and a plurality of upwardly extending sidewalls, wherein at least a portion of the cargo box floor extends over the at least one cargo box support member and wherein the cargo box is removably coupled to the at least one cargo box support members and is removable from the off-road vehicle via the removal of fewer than eight fasteners.

Abstract: An off-road vehicle includes a frame, a front suspension, and a rear suspension. In some examples of the off-road vehicle, the rear suspension includes trailing arms with are pivotally attached to the frame rearward of an operator area. Further, the frame can include a front subframe assembly and a rear subframe assembly which are easily removable from the main frame of the vehicle to permit access to various components of the off-road vehicle.

Abstract: An apparatus and methods are provided for a transmission for a rear mid-engine vehicle. The transmission comprises a power transfer portion for receiving torque from the engine and a gearbox for providing conversions of rotational speed and torque. First and second side output portions conduct torque from the gearbox to the rear wheels. A forward output portion conducts torque to front wheels of a four-wheel drive vehicle. An air clutch comprising each output portion controls the degree of torque transferred to each wheel. The output portions are each coupled to a rear wheel by a rear axle, bevel gears, and rear portal gears. The rear axles are aligned with, and positioned above, the trailing arms to protect the rear axles from damage due to rocks and debris. The length and alignment of the rear axles cause CV joints to articulate in the same direction as the trailing arms.

Abstract: An apparatus and methods are provided for a portal spindle assembly for a vehicle front suspension. The portal spindle assembly comprises a spindle portion that is rotatably coupled with upper and lower connecting arms. A leading-edge portion is rotatably coupled with a steering rod-end joint, such that moving the steering rod-end joint rotates the spindle assembly with respect to the upper and lower connecting arms. An inboard case and an outboard case support a pinion gear assembly that is meshed with an output gear assembly for communicating torque from a constant velocity joint to a front wheel coupled to the output gear assembly. The pinion gear assembly is aligned along a pinion axis disposed at an angle with respect to a hub axis of the output gear assembly. The angle facilitates a suspension geometry that provides a camber change of the front wheel that eliminates a change in track width.

Abstract: An apparatus and a method are provided for an offset tie rod joint for vehicle steering systems. The offset tie rod joint comprises a ball rotatably retained within a casing that is disposed in an opening of an offset housing. A threaded shank fixedly coupled with the offset housing is received by a steering rod. The opening is displaced from a longitudinal axis of the threaded shank by a distance that provides clearance between the offset housing and a spindle assembly during articulation of the spindle assembly during steering. A rear backstop and a front snap-ring in a groove retain the casing within the opening. A bore extending through the ball receives a bolt that fixates the ball between parallel prongs of the spindle assembly. A misalignment spacer on each side of the ball provides clearance for rotation of the ball within the offset housing.

Abstract: A modular chassis is provided for an off-road vehicle to improve assembly, servicing, and repairing of a drivetrain of the off-road vehicle. The modular chassis includes a chassis to support components of the off-road vehicle. A front frame module couples with a front of the chassis, and a rear frame module couples with a rear of the chassis. The front frame module supports lower suspension arms of the off-road vehicle by way of inboard bushing joints. The front frame module supports at least a steering gear and a front differential of the off-road vehicle. The rear frame module is a tube-frame structure that supports components of the off-road vehicle. A lower portion of the rear frame module extends rearward and acutely upward to a top frame member that couples with upper side portions of the chassis. Several cross-members impart structural integrity to the rear frame module.

Abstract: A constant velocity housing is provided to couple a plunging CV joint with a transaxle. The constant velocity comprises an elongate housing configured to retain the plunging CV joint and a splined shaft configured to engage with a transaxle. A locking system removably retains the splined shaft within the transaxle. The locking system comprises a lock pin in mechanical communication with pins slidably retained within radial holes disposed in the splined shaft underneath a snap-ring. An actuator moves the lock pin to push the pins to operably change a diameter of the snap-ring. When the actuator is loosened, the snap-ring constricts to a diameter less than the diameter of the splined shaft, allowing removal of the splined shaft from the transaxle. When the actuator is fully tightened, the snap-ring assumes a diameter greater than the diameter of the splined shaft, such that the spline shaft remains engaged with the transaxle.

Abstract: An apparatus and methods are provided for a chassis for an off-road vehicle that includes a chassis strut support. The chassis is a welded-tube variety of chassis that includes a front portion and a rear portion that are joined to an intervening passenger cabin portion. The chassis strut support includes one or more pairs of rear strut gusset plates for distributing loading on a rear strut crossmember by rear struts to at least a seat crossmember comprising the chassis. The rear strut gusset plates generally comprise thick sheet-members configured to be attached to a vertical brace between an upper mount and a lower stay comprising the chassis to reinforce the vertical brace and impart increased strength to the chassis. The rear strut gusset plates are configured to be attached to the vertical brace by way of bolts, rivets, welding, or any combination thereof.

Abstract: A rod-end front suspension is provided for an off-road vehicle. The rod-end front suspension comprises a spindle assembly that is pivotally coupled with an upper suspension arm by way of a first rod-end joint and pivotally coupled with a lower suspension arm by way of a second rod-end joint. A steering rod-end joint coupled with the spindle assembly pivotally receives a steering rod. An axle assembly coupled with the spindle assembly conducts torque from a transaxle to a wheel coupled with the spindle assembly. Each of the first and second rod-end joints comprises a ball rotatably retained within a casing. The ball is fastened within a recess between parallel prongs extending from the spindle assembly. A threaded shank extending from the casing is threadably fixated with the suspension arm, such that the spindle assembly may be moved with respect to the casing and the suspension arm.

Abstract: A leading-edge steering system is provided for a front suspension of an off-road vehicle. The leading-edge steering system is comprised of a spindle assembly that supports a drive axle assembly to conduct torque from a transaxle to a front wheel. A first rod-end joint pivotally couples an upper suspension arm and the spindle assembly, and a second rod-end joint pivotally couples a lower suspension arm and the spindle assembly. A steering rod-end joint pivotally couples a first end of a steering rod with a leading-edge portion of the spindle assembly. A steering gear is coupled with a second end of the steering rod and configured to move the steering rod, such that the spindle assembly rotates with respect to the upper and lower suspension arms. The leading-edge portion is configured to exert primarily tensile forces on the steering rod during travel over rough terrain.