1. Construction Material

EMG chooses to use aircraft quality Australian aluminium

• 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 staircases simulating steps and gutters found in and around golf courses.

The EMG designed frame has the fundamental principals of load bearing directions in mind. One 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" has to tolerate the weight of several items at once, the golf bag (up to 20 kilograms) battery (9 kilograms) and motor/gearbox assembly without fracturing away from the lower handle and axle components. The EMG design ensures that all loading pressures from this common movement are evenly distributed throughout the entire chassis rather than concentrated in one location. Most manufacturers have assistance bracing from the handle to the chassis to combat this common loading, but these are unsightly, add clutter and spoil the look of a motorised 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 superior 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. We were told by a customer that they were experiencing difficulties when having to continually bend over or duck down in order to move under the umbrella mounted to their golf buggy, even though an extra hand had been used. The manufacture of their motorised golf buggy simply had not taken into account that all people vary in height. We assessed this problem and it was apparent all manufactures have this same problem. Therefore, EMG found a solution for this customer, and then made this item a standard feature of all future Evolution Motorised Golf Buggies.

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 relies on a 24amp/hr full deep cycle battery. The 24amp/hr battery supplied has stood up to all tests in which EMG have put batteries through. The use of a 24amp hour battery, selected to perfectly match the gearbox and drive line assembly. 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, in fact 30 continuous holes has been achieved.

7. Wheels

Uniquely designed and produced from injection moulded dies. The wheels are produced from a 2 part process. Hub area and spokes are produced and then manually put back into the die to fuse the slick rubber to the outside.  No consumable plastic or rubber sleeves to replace or possibility of delamination like a worn out car tyre. Superior Quality, with a 5 year warranty that is not matched by any other manufacturer.

8. Wheel Bearings

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.

9. Suspension

Suspension is an important element of any type of vehicle. It has to absorb and dampen the impact from the surface over which it is travelling and is important for making a smoother ride. EMG suspension is what we like to point out to customers as true suspension. It is not simply a rubber block attaching the front wheel to the chassis as some manufactures provide. Our suspension material is sourced within Australia and is already at a spring steel state or compound before being shipped to Newcastle where it is then sent to be laser cut into the shape required for the final product.