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Dirtbike Swingarm

Students on Project: Justin Menendez and Nolan Ellrott

ManuFacturing

image_2026-03-02_164539838.png

Side view: Frame on jig

Jig

  • Used to constrain tubes, nodes, and mounts during welding

  • L-blocks and locating plates for shock mount

  • Aluminum spacer for locating axel nodes

  • Alightment pins/blocks for locating tubes

  • Aluminum alignment rod for locating frame nodes

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Tubes and Plates

  • Manufactured by students in Ware Lab

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Shock Mount

  • Manufactured by students in Ware Lab

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Frame and Axel Nodes

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Welding

  • ​Frame will be tacked by students on jig

  • Then sponsor ConnWeld in Princton, WV will complete welding​​

Design

image_2026-03-02_163805971.png

Near finalized swingarm design

General Notes​

  • Front forks

    • Stock WP forks​

    • 8765-47 springs

    • Stock KTM triple clamps​​

  • Rear shock​

    • Stock WP XPLOR PDS shock​

    • 72/75/78 N/mm progressive spring​​

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Materials

  • 4130 rectangular tube

  • Bent vs Cut+Weld

  • 4130 plates for crossmember​​

  • 4130 threaded standoffs for rear shock mount

  • 6061 aluminum shock mount

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Rear Axel Nodes

  • Welded connection to tube structure

  • Threaded hole into tube for adjustment bolt

  • Axel slot for adjustment

  • Pocket for adjustment blocks

Planning

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Early swingarm design

​General Notes

  • Swingarm needs to be designed around a motor coaxial with swingarm pivot point

  • Suspension needs 300mm of travel

  • Factor of saftey of at least 1.3​

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Major Considerations

  • Suspension Type

    • Linkage​

    • PDS

  • Manufacturing method

    • Cast​

    • Welded

  • Material

    • Aluminum​

    • Steel

  • Layout​

    • Symmetric​

    • Asymetric

  • Mounting​

    • Inside frame​

    • Outside frame

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