1. Construction Material

EMG chooses to use aircraft quality Australian Made Ullrich aluminium Newcastle.

• Aluminium has excellent strength qualities.
• Overall, weight is kept to a minimum.
• Aluminium does not rust therefore if sand or water enters any of the structural components no deterioration will occur guaranteeing product longevity.

2. Strength

To achieve exceptional strength properties for a "Chassis" the design has to include a number of factors, the type of material, what type and how much bracing and the type and quality of welding.

The EMG chassis is a product of extensive testing carried out both on and off the golf course. As an example of our off course testing, our chassis is subjected to repetitive motions such as moving up and down stairs simulating steps and gutters and extremely ruff surfaces found in and around golf courses.

The EMG designed frame has the fundamental principals of load bearing directions in mind. An example of the extreme load that a motorised golf buggy experiences, is when the user pulls backward and down on the top t-handle lifting the front wheel off the ground. The lower frame or "chassis" that is contact with the axle housing, has to tolerate the weight of several items at once, the golf bag (up to 20 kilograms) battery (9 kilograms) and motor/gearbox assembly. The EMG design ensures that all loading pressures from this common movement are evenly distributed throughout the entire chassis via structural plates that embrace the axle housing, sump and main frame, rather than being welded to the axle housing alone. Most manufacturers have assistance bracing from the handle to the chassis, due to undersized tubing they need extra help to stop the handle from folding under weight from the bag and the pressure from turning the buggy from left to right and to get over objects such as gutters etc and they also spoil the look of a golf buggy. Other manufacturers choose not to brace at all, which inevitably leads to the axle housing fracturing away from the chassis.

3. Welding

The welding of any component is very important whether it is a golf buggy, lawn mower or competition racing car. The method that EMG uses is "TIG" welding, a world class form of welding used on competition vehicles, including Formula 1, all over the world. Many factors work together with "TIG" welding. A precise temperature is needed before the filler rod can be added ensuring that penetration of both components has taken place. Once the welding process is completed on components, no further preparation of the welds is needed before being sent off to the final phases of production. No other welding process can match this.

Other welding processes are suited mostly to fast production of components, this is usually achieved using "MIG" welding, which is a good welding process, but can often have inconsistent penetration, therefore is not suited to intricate component welding that is found in motorised golf buggies. Imported buggies are a classic example of where fast production welding is used; the result is an old cliché "you get what you pay for."

4. Extra Hand Adaptor

This simple yet ingenious idea came about when the team at EMG received a request. Customers told EMG that they were experiencing difficulties when having to continually bend over or duck down under the umbrella mounted to their golf buggy, even though an extra hand-or umbrella holder, had been used. We spoke with a few of our customers about this minor but silly problem, we came up with the solution of running the extra hand on the highest piont of the handle, offset to the side so it is not right in front of your face. The best posative to utalising this positon is that if its a raining/overcast/raining type of day, which we all encounter from time to time on the golf course, you can simply fold down your brollie, leave it in the extra hand and adjust the extra hand down the side of your bag. Then if it rains agian, all you have to do is, readjust the extrahand into the most upright position and open your brollie into the open position, then you are covered for the next shower. (No pulling out of your bag and reasembling the whole set-up) Most manufactures have the umbrella holder clamped half way down the top handle, which in turn you lose up to 6 inches from the top of the handle.

5. Drive Assembly

a to c explains the difference between 3 types of gearbox available and why EMG chose a worm – helical combination, taking the strength of a worm and efficiency of the helical.

a. Worm Drive Gearbox

The worm drive, designed primarily for use in heavy engineering, was initially conceived in the 1800's. The main problem associated with this gearbox is drag or friction. A worm drive gearbox has 3 teeth in mesh at any one time, which in turn causes excessive drag, therefore the motor has to work harder to compensate. A motor working harder than necessary causes increased strain on the battery, which in turn leads directly to much shorter battery life and less power to make that final tee off.

b. Helical Gearbox

The helical configured gearbox primarily used in motor vehicles. This gearbox when configured correctly has only 1 tooth in mesh and is very efficient with minimal drag. The problem that manufacturers of motorised golf buggies have is restrictive size gearbox housings. Configurations using up to 4 gears to acquire final drive ratios have to be used which in turn eliminates all efficiencies due to the fact 4 teeth are in mesh. Manufactures are forced to use small diameter plastic gears with delicate .08 of millimetre fine-pitched teeth, which often fail through normal wear and tear.

c. EMG Unique Gearbox

EMG is aware of the benefits and failures of both worm drive and helical configured gearboxes. Our solution has been to take advantage of the strong points of the worm and helical. EMG opted for a worm – helical combination, taking the strength of a worm and efficiency of the helical. The EMG gearbox has only a pinion gear and main gear, this lends itself directly to be able to achieve the maximum diameter main gear with a massive 4mm tooth depth.
This depth is only comparable to those found in your motor vehicle. EMG is extremely confident with the design and a 2 year warranty is provided.

6. Battery

EMG use a standard 24amp/hr full deep cycle battery. The 24amp/hr battery supplied is for the golfer that plays 1-2 days a month playing 9- 18 holes.(6 months Warranty) EMG have an optional upgrade to a 28amp/h Sonnenschein Gel battery at a small additional cost. Sonnenschein is the world leaders in Gel battery technology and it also helps our buggy travel further than your standard 18 holes on hilly courses.(12 months Warranty)Testing has brought about results such as on very hilly golf courses the EMG had ample battery power still in reserve, which allows the buggy to continue well past 18 holes.

7. Wheels

EMG 5 spoke injection rear wheel with rubber overlay, designed for strength and durabilty for ruff courses. The spokes are a + design to give extra strengh from forward and sideways motions and bumps that occur on fairways and paths in between. The wheels are produced from a 2 part process. Bearing hub area(Wheel Centre) and spokes are moulded in the same process for strength. Once this procedure is complete the wheels are put through a process which is manual. The injection moulding operator puts each individual injected carcaus into the machine for the rubber to be injected to the outside. This leaves no consumable plastic or rubber sleeves to replace, or possibility of delamination like a worn out car tyre. Superior Quality, with a 2 year warranty that is not matched by any other manufacturer. Wheels are produced by;

Deeps Engineering Salmander Bay Newcastle NSW

8. Wheel Bearings & Drive Axle

Rear axles are a common problem on Electric Golf Buggies, as this is where all the load and shock from surfaces is absorbed.
All imports have a 12mm axle which connects to the main gear of the gearbox via a roll pin which is uasually the shear piont under load and bumps.

(Most don't use Hi Tensile Rollpins).

They also have a machined groove at the end of the shaft for the mechanism for the removable wheels, which creates another problem.
The axle is already 12mm then you machine a groove 3-4 mm deep for the keyway for the wheel to be removed. Now you have reduced the axle to a minimum of 8mm. From common sense and customer experience EMG know that this set up and designs create a shear point as the quick release wheel that runs on the shaft is steel on steel.
We have tried and tested 12mm axles and after a couple of games the end of the axles bend where the wheels locate. At EMG we use 15mm bright bar material for our axle. (Never Broken 1).
The drive bearings are Needle roller clutch bearings that connect through a hexagon drivenut that drives the wheels when the motor is turned to on. This setup works the same as a differential in a car, turn left to right each bearing will disengage to make manourabilty easy.

From previous reading you would have read that we use an imported gearbox/motor assembly.
It has a 12mm hole through the main gear. We have an alignment jig that we place the gears into on a lathe, to re-drill them out to 15mm. so that you can have added strength.
Wheel bearings are an important factor for longevity of a motorised golf buggy. EMG's rear wheels are supplied with, needle roller clutch bearings in each wheel, that helps turning mobility. When the buggy is not turned on it can free-wheel forward and backwards with ease. How this system works is once the motor is engaged via the On/Off switch the needle roller bearings engage onto the axle, giving you drive through both wheels for traction up steep hills and slippery surfaces. If you need to turn the buggy left to right the clutch bearings will disengage for optimum turning ability. The needle roller is fully supported in the wheel with 2 ball race bearings suitable for a standard car gearbox.

Bearings in the front wheel of the EMG buggies have spacers between the bearings to ensure that no matter how much torque is applied, the mounting bolt and bearings will never operate outside there torque parameters.

EMGs entire drive assembly only use sealed ball race bearings not cheap plastic bushes.