Here is my design. It's the same concept as many others, just different geometry for parts.

The parts are designed focusing on material reduction and simple geometry, in order to require easy bend procedures and produce more parts per sheet of metal. Check the Parts List file to observe required parts (Look under “Description” column, the ones that say: “Manufacturing Required”). The list also specifies all standard parts such as U-bolts, Hex bolts, Nuts and Washers.

I did some FE stress analysis to check the axle’s load capacity. The square Tube (50x50x3) resists the 1850 kg load and a maximum braking torque per wheel of 575 N.m, with a safety factor of 2. The Spring Support was also analyzed. The material used was ASTM A36, Yield Strength 250MPa.

The only welded part is the Torsion Support, which is welded to the axle square tube.

A couple of design revisions can be performed to tune up the model if needed.

Any comments/feedback are welcome.

Cheers!