Project Overview
The V2HO is a complete independent rear suspension system developed by Xdrift Industries through CAD design, component development, machining, fabrication and physical verification. The project integrates the subframe, control arms, rocker-operated suspension, differential mounting, hubs, hand brake assembly and driveline components into one engineered assembly.
The V2HO was initially developed to fit the Australian Ford XD Falcon chassis. Its suspension geometry was derived from the AU Falcon independent rear suspension, selected for its linear wheel movement through the intended suspension travel. The system was then redesigned around a cantilever-operated suspension layout, with the rocker geometry developed to produce a rising-rate motion ratio as the suspension compresses. Differential position, driveline alignment, component packaging, serviceability and fabrication requirements were considered together as part of the complete assembly.
Custom Rocker-Arm Bearing Assembly
A suitable off-the-shelf rocker pivot solution could not be found without using prohibitively expensive needle-roller thrust bearings. Xdrift therefore developed a serviceable bearing assembly using commonly available, lower-cost bearings. A castellated adjusting nut allows the assembly to be preloaded to minimise free play while retaining practical maintenance and replacement options.
Control-Arm Development
The upper and lower control arms were developed specifically for the V2HO system, translating the selected AU Falcon suspension geometry into a package suited to the XD Falcon chassis. They are fabricated from 4130 chromoly tubing measuring 1⅜ inches outside diameter with a 0.120-inch wall thickness. Custom tube geometry, rod-end mounting, machined spacers and fabricated brackets were developed together to provide the required wheel path, adjustment and component clearance throughout suspension travel.
Frame Fabrication and Verification
The V2HO frame was fabricated around the suspension geometry and component locations established in CAD. During assembly, the mounting points, bracket positions and overall alignment were checked against the design before final welding. This verification process helped ensure that the fabricated structure accurately located the control arms, rocker system, differential and hub assemblies.
Bracket Fabrication and TIG Welding
Purpose-built laser-cut brackets and mounts were developed to integrate the suspension components into the V2HO frame. Careful fit-up, accurate positioning and TIG welding were used to maintain alignment while producing clean, consistent joints. This work demonstrates the fabrication capability behind the project, complementing the CAD design, machining and suspension-development processes.
Completed Assembly
The completed V2HO assembly brings the fabricated frame, control arms, rocker-operated suspension, differential mounting, hubs, brakes and driveline components together as one integrated rear suspension system. The finished structure demonstrates the progression from CAD design and machined components through fabrication, verification and final assembly.
Project Outcome
The V2HO demonstrates Xdrift Industries’ ability to develop a complex suspension concept from initial geometry and CAD modelling through component design, machining, fabrication and completed prototype assembly. Developed initially for the Australian XD Falcon chassis, the project combines practical engineering, serviceable component design and purpose-built fabrication into one integrated rear suspension system.