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Axle mock-ups complete. Need to send them out now to get reproduced as one piece. Pictures represent CV angle at a 1" drop ride height.

Also want to get everyones opinion on the path forward... The deeper I get into this project, the more painfully obvious it is that the aftermarket support just isn't there yet for an EV build. Things that I would consider major requirements like fast charging, vehicle integration, reliability...

CV joint cut down and features added back. Also made an adapter for the GT4 CV boot. Only CV boot that I have been able to find so far with this much thinner design. Hopefully this will allow me to avoid having to notch the control arms....

Looks great! What brand fenders are these if you don’t mind me asking? Been looking for wider fenders without needing the GT350/500 core support and bumper.

Got the custom toe arm brackets from sendcutsend welded in. I intend to use adjustable toe arms instead of the factory alignment bolt. Now back to the CV axle issues...

Fun little easter egg I found on the motor this evening.

Well as expected, I cannot use the Mach E haft shaft directly with the S550 outer CV... 3mm difference in diameter at the splines (s550 being larger....) So custom half shafts it is... Yay...

I’d say the S550 half shafts were designed for a bit more power…. Good thing is my cut down inner CV is identical in length to the OEM S550 inner CV. That should hopefully mean I’m good on plunge distance with the CV. Going to try to combine these half shafts this weekend. Modified Mach E inner...

Difference in length between driver and passenger CV axle for the Mach E.

I think we have a solution. Control arm will still need to be notched to clear the CV boot but shortening the inner CV by 25mm worked. Just enough plunge distance for the most extreme control arm angle I could simulate (unrealistic in a street car, ball bearings which transfer rotational energy...

The issue might have been exacerbated by my choice of S650 control arms instead of S550. On a normal car they are interchangeable but it appears that the casting is just different enough in the wrong places to make the issue worse. Passenger side with an S550 control arm is much closer to...

Plunging 8 ball as expected.

I believe it is identical to the Mustang cv unit. Once I get one disassembled, I'll post a few pics. I'm thinking based on the travel it currently has, I can get away will cutting about an inch off.

That would be the ultimate setup. The issue is that drive units of that size and power density don't quite exist... Yet... The YASA 750R gets close and I actually looked at using two of these stacked in the center of the existing subframe. You need a motor with ALOT more torque to account for...

Yep they do for a Tesla, not a Mach E drive unit from what I have seen thus far. What I will essentially try to do though is take the OEM inner CV and modify it to match the 930 dimensions as much as possible.

Yep, this is why I didn’t go with swapping in a Tesla subframe initially.

That sure is an idea! One funky rear suspension design but extremely simple and gives a TON of room for motor. 800hp Plaid rear motor even… Track width would need to be addressed but would be fairly simple to create a custom widened subframe.

Just about 30lbs each. So for a 21 module battery, 630lbs in modules. A 24 module battery would be 720lbs. Just estimating a casing around 100lbs for the time being would mean a roughly 750lbs battery at the minimum.

Raising the drive unit higher isn't an option. It might solve the lower control arm issue but then I run into an issue with the upper camber arm. The main problem here is the drive unit is too wide for the ridiculously narrow S550 subframe... I might try to modify the inner CV to reduce its...

Well, sh*t…. That’s a problem… Worst fear came true…