Simple/low-cost Electric go kart conversion

[Functional Artist]

Double check ALL connections

...for correctness

...& tightness


Loose lips may sink ships

but, loose connections get hot & melt stuff


Lets give 'er a try

https://www.youtube.com/watch?v=rZBAPc9Jl5M

 

[Functional Artist]

I wasn't happy with the return action of the pedal actuated thumb throttle

Will tinker with it & adjust later

Here is another idea

Just mount the thumb throttle on the steering wheel

...with a piece of pipe & a small U-bolt

 

[ezcome-ezgo]

I thought that throttle set-up looked a little sketchy. But you are rockin' it now!

 

[Functional Artist]

Time for some testin'


But, wait

If were gonna gather some data

We gotta get our meter hooked up

So,

I mounted the shunt onto a plastic base

...strapped it to the bat trees

...hooked the side labeled "battery" of the shunt to the negative (-) terminal of the bat tree pak

...hooked the negative battery cable (formerly went to bat pak negative) to the side of the shunt labeled "motor"

...hooked the meter lead wire to the positive (+) wire going into the motor

Yup!

Now were ready


https://www.youtube.com/watch?v=1_9XMrJohm8

 

[Functional Artist]

First test run

Kart: e-Lemon-aid

Motor: 24V 450W DC brushed motor (Turbo stressed)


avg amp draw: 15A

max amp draw: 31A

max speed: 11 mph

Run time: ~40 min.


https://www.youtube.com/watch?v=n1aysgJYGQ8

 

[Functional Artist]

Mounted up another

24V 450W (non stressed) motor

on e-Lemon-aid


The data was pretty much the same

but, the top speed was lower (~9 mph instead of ~11 mph like before)


I was expecting better performance

NOT worse ???


avg. amp draw: 15A

max amp draw: 30A

max speed: 9 mph

run time: ~40 min.

https://www.youtube.com/watch?v=uBT9B0sqNe4

 

[Functional Artist]

Next,

Were gonna step it up a bit

Were gonna jump up to a MY1020 48V 1,000W brushed DC motor

It's rated current is 26.7 amps & it is speed rated at 3,000 rpm's

I had to do some adjusting, the sprocket was off about 1/4"


https://www.youtube.com/watch?v=ZxFo0T8Upm0

 

[Functional Artist]

Test run was fun

This 48V 1,000W motor is very perky/torquey.

It zips to 10 mph like quick

It moves right along & seems to transverse grass as well as it does pavement.

With this set up it speed tops out at just under 15 mph

The meter showed that it drew ~25A at take off and averaged ~8A most of the ride.

https://www.youtube.com/watch?v=AxKkIaE2feY

 

[alim]

Did the kart come with that axle sprocket?

 

[Functional Artist]

Did the kart come with that axle sprocket?

Yup, looks like the factory sprocket that's been on there for years

It has an 84 tooth axle sprocket & a 10 tooth motor sprocket for an 8.4:1 ratio

Very torquey (if that's even a word)

---------- Post added at 11:01 PM ---------- Previous post was at 10:36 PM ----------

Well, someone seems to be impressed with what we are doing


This message was left on the 48V 1,000W test drive video

Awsome!. This is Mike from Alfa Wheels. Please visit my ebay store and mention this video, I will give you a 10% discount for any item not already discounted. http://stores.ebay.com/alfawheels1.


Clean, powerful & discounts

 

[alim]

Well, someone seems to be impressed with what we are doing


This message was left on the 48V 1,000W test drive video

Awsome!. This is Mike from Alfa Wheels. Please visit my ebay store and mention this video, I will give you a 10% discount for any item not already discounted. http://stores.ebay.com/alfawheels1.


Clean, powerful & discounts

I've seen their ads on eBay, they have really great prices on motors. Based out of Florida.

 

[Functional Artist]

Did some more testin' today

So far, 48V is the way to go!

It scoots right along on pavement & off road

...& it even does burn outs


Way more powerful & draws less from the bat trees

Double bonus


https://www.youtube.com/watch?v=6r_hVhQu6Qk

 

[alim]

Lol I think I know my way around your neighbourhood almost as well as you do

 

[Functional Artist]

Talking about the Boma 48V 1,800W brushless motor earlier made me think,

I haven't got El Dingo II out lately

I want to mount the Boma motor on e-Lemon-aid to get some data

But, I wanna have some fun first

So, lets get 'er out-n-play today

https://www.youtube.com/watch?v=WJDsVtMJCdg

 

[Functional Artist]

I mounted the Boma 48V 1,800W brushless motor & controller on e-Lemon-aid.

I made a terminal cover/pouch to help make a safer kart

It will cover up the open terminals on the motor terminal connection port & I can tuck the other plugs in there also to help protect our other connections too.


The data seemed to be close to the 48V 1,000W brushed motor

avg amp draw: 8A

max amp draw: 29A

top speed ~15 mph

https://www.youtube.com/watch?v=3yzOS4cE424

 

[Functional Artist]

Hold the presses!

"This just in" New information

A message has been left on one of the e-Lemon-aid videos that says:

"The diagram leaves out the "stalls" wiring which is important as it sets the RPM of the motor. If its not connected it runs at middle speed and not at its full RPM."


So, after doing more research, it seems that the "stalls" plug is for a (3) speed switch


If you connect the black & blue wires you get low speed ~2,680 rpm's

If nothing is hooked (like I have it now) it runs at med speed ~3,450 rpm's

& if you connect the black & green wires the motor runs at it's highest speed ~4,150


Yup!

Ima doin' some testin' tomorrow

Stay tuned

 

[Functional Artist]

Well, we have another translation

..."stalls" means (3) speed switch


So, if you want to have full speed always available

...just connect the green & the black wires


But, to make this feature fully functional

...you will need an on/off/on switch

https://www.youtube.com/watch?v=V6u8LLgIAgc

 

[MadManAndrew]

Here’s a cable pull throttle specifically for conversions like this. https://electricscooterparts.com/throttlesstandard.html#cablepullhrottle

 

[Functional Artist]

Here’s a cable pull throttle specifically for conversions like this. https://electricscooterparts.com/throttlesstandard.html#cablepullhrottle

Yup, that's a great solution

It makes it easy to hook up to the stock (gas) pedal & provide throttle signal input to your electric motor controller.

It eliminated the need for goofy looking (add on) pedals &/or twist & thumb throttles.

 

[garolittle]

Great videos. I watched the first 11 today and will finish the rest tomorrow. Thanks for postingbthese.