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: 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 front structural bulkhead for improving the strength of an off-road vehicle chassis. 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. Frontward stays and a bulkhead mount couple the front structural bulkhead to the front portion. Bulkhead mount pillars and a bulkhead mount crossmember couple the front structural bulkhead to the passenger cabin portion. The front structural bulkhead includes a modular chassis for supporting drivetrain components that are operably coupled with front wheels of the vehicle. The front structural bulkhead includes upper and lower mounting points configured to receive front suspension controls arms. The upper and lower mounting points are configured to allow the front wheels to move vertically due to the vehicle traveling over terrain.

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 rear portal trailing arm assembly for a vehicle rear suspension that includes a CV joint hub for coupling with a transaxle and a wheel hub for coupling with a rear wheel. A gear transfer case extends rearward from the CV joint hub to an axle case and functions similarly to a rear trailing arm. Forward mounts facilitate coupling the gear transfer case to the chassis such that the trailing arm assembly pivots vertically with respect to the chassis. A rearward mount facilitates coupling a strut with the gear transfer case to control the vertical motion of the rear wheel. Multiple gear assemblies are meshed within the gear transfer case. An axle is coupled with the meshed gear assemblies and housed within the axle case, such that torque applied to the CV joint hub is communicated to the wheel hub.

Abstract: A dual plunging constant velocity (CV) drive shaft is provided for communicating rotational forces from a transaxle to a drive wheel of a vehicle. The dual plunging CV drive shaft comprises a drive shaft that transfers torque from the transaxle to the drive wheel. An inboard plunging CV joint is coupled between the transaxle and the drive shaft, and an outboard plunging CV joint is coupled between the drive shaft and the drive wheel. The inboard and outboard plunging CV joints each comprises an elongate housing that receives a CV joint coupled with the drive shaft. The inboard and outboard plunging CV joints communicate rotational forces from the transaxle to the drive wheel during vertical pivoting of a trailing arm coupled with the outboard plunging CV joint. The elongate housings allow the drive shaft to “float” longitudinally, as needed, during extreme pivoting motion of the suspension.

Abstract: An apparatus and methods are provided for an air-cooled CVT clutch. The air-cooled CVT clutch includes a first cooling fan coupled with a primary clutch and a second cooling fan coupled with a secondary clutch. An outboard housing mates with an inboard housing to enclose the primary clutch and the secondary clutch. The first cooling fan is coupled to a moveable sheave comprising the primary clutch and configured to draw a cooling airstream through an air duct disposed in the outboard housing. The second cooling fan is coupled to a moveable sheave comprising the secondary clutch and configured to draw the cooling airstream from the primary clutch to the secondary clutch. The first cooling fan pushes the cooling airstream to the secondary clutch when the second clutch is not rotating.

Abstract: An apparatus and methods are provided for a chassis for an off-road vehicle that includes A-pillar supports. 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. A front canopy is coupled to the front portion and reinforces the chassis during loading forces due to front struts. Each of the A-pillar supports includes a vertical brace disposed between the front canopy and a side brace of the vehicle. The vertical brace extends downward from the front canopy, adjacently to an A-pillar and a hinge pillar, to the side brace. The frontward stay extends forward from substantially a midpoint of the vertical brace to a joining of the A-pillar and the hinge pillar. The A-pillar supports reinforce the front canopy and provide structural integrity to a front of the passenger cabin portion.

Abstract: An apparatus and a method are provided for a camber adjustment assembly, comprising: first and second end plates coupled to a substantially planar center portion, wherein the first and second end plates comprise a generally triangular configuration; a chassis element coupled to a trailing arm and the camber adjustment assembly, and wherein a force may be applied to the camber adjustment assembly so as to desirably induce a positive or negative camber condition.

Abstract: An apparatus and methods are provided for a chassis for an off-road vehicle that includes a roll cage chassis structural 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: An apparatus and methods are provided for a chassis for an off-road vehicle that includes roll cage center supports. 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 center supports include angled braces for counteracting lateral forces on a canopy of the vehicle during a rollover event. A center roof bar disposed along a midline of the canopy provides overhead protection to occupants within the passenger cabin portion. Windshield braces within a windshield area of the canopy reinforce a front of the center roof bar. A rear of the center roof bar is reinforced by roof braces within a rear of the canopy. The windshield braces and the roof braces support the center roof bar so as to withstand forces exerted on the canopy during a rollover event.

Abstract: An apparatus and methods are provided for a bead-locking wheel for mechanically coupling a tire to a wheel rim of an off-road vehicle. The bead-locking wheel includes a barrel for mounting the tire and a bead lock face for fastening the barrel and tire to a wheel hub of the vehicle. The bead lock face is fastened to a shoulder disposed around an outboard end of the barrel. The shoulder and an outboard flange of the barrel cooperate with a periphery of the bead lock face to mechanically retain an outboard bead of the tire. Mechanically retaining the outboard bead facilitates a relatively low inflation pressure within the tire to accommodate off-road conditions and high tractive forces. The bead lock face maximizes a positive offset and backspacing of the bead-locking wheel to accommodate a relatively wide hub and spindle assembly while maintaining an advantageous steering geometry and track width.

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.