2020 - Excalibur Electric Racing kart

Functional Artist

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I watched a movie the other day with the family, called "Go Kart's" :thumbsup:
...it was about go kart racing :auto:

I must have told my wife (10) times "I could do that" :wai:
...not really racing (well maybe, who's gonna test 'er)
...but, to build a racing (style) kart


https://www.youtube.com/watch?v=do99iDsfnJY

So, I've been doin' some research
…& come up with some ideas/plans :cheers2:

I'm gonna call 'er Excalibur (ek 'skaeliber) :sifone:
...it's Caledfwich in Welsh
...or Caliburnus in Latin

* Excalibur is known as the legendary sword of King Arthur, sometimes attributed with magical powers. ;)

So this kart is gonna slice thru the air "like a knife"
…& have electrical "powers" runnin' thru it's "veins" :cool:

Besides the name & a plan, I have rounded up
...a live axle
...a racing style seat
...a 48V 1,000W motor
...& some 1/2" schedule 40 (water) pipe :2guns:


** Also, challenge accepted "It's on" :stir:
...Hillbilly, I comin' for you (imagine Mr.T "barking" at Rocky) :smartass:

It might take a while
...but, I'm headin' in that direction :devil2:

So, let's get started :popcorn:
 

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Functional Artist

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I started measurin', markin', cuttin' & bendin' :thumbsup:
…& then, some arrangin' & aligin' :cheers2:

She's startin' ta take shape :2guns:
 

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Functional Artist

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I cut & screwed down some "alignment boards" to help keep everything "in place"
…& then, marked where the "outer" rails intersect with the "inner" rails :thumbsup:

* The mark toward the ends, is where they get cut off
...the other mark indicates the depth of the "fish mouth" :2guns:
 

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Functional Artist

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Next we needs to angle up the front of the frame, just a bit, on each side
…& then, we can weld the outer rails, to the inner rails :thumbsup:
(used a board to help keep 'em aligned)

Also, attached the spindle brackets
...angled 'em back just a bit
…& inward just a bit too :2guns:
(used another board to help keep 'em aligned in this direction too) :cheers2:

* All (4) wheels will be the same size (10.5" x 6" Unelli's)
...so, the spindle height has been adjusted accordingly, to align with the rear axle height
 

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Bansil

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I really liked the movie :thumbsup: would watch others like it, reminded me of movies from the 80's, you know...fun ones

That Kart is awesome! Great build so far, I hope to start on something but way to much work now 50+ hours a week
 

Functional Artist

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I really liked the movie :thumbsup: would watch others like it, reminded me of movies from the 80's, you know...fun ones

That Kart is awesome! Great build so far, I hope to start on something but way to much work now 50+ hours a week

Thanks! :thumbsup:

Kinda reminded me of The Karate Kid
...just about go kart racing :cheers2:

Here in Ohio were still under "Shut Down/Stay at Home Orders", till May 1st.
...so, I'm gettin' stuff done (while I can) :2guns:
 

Functional Artist

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Made lots of progress :thumbsup:

First, I bent up a piece for the front of the frame (lower front bumper)
…& aligned & welded 'er on

* Check out "the slope" of that front bumper/spoiler :cheers2:

Then, I cut & welded in a front "cross member"
...a kinda diagonal rear "cross member"
…& also, (4) short "cross members"

She's startin' to look fast already :2guns:
 

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Functional Artist

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Workin' our way forward, we have established where the rear axle is gonna be
…& have an idea where the motor(s) are gonna go :thumbsup:

So, next would be to get the seat mounted

I'ma goin' "off script" for this :cheers2:

Yup, I'ma gonna incorporate/install my "signature" seat back/roll bar :cool:
...to mount/support the back of the seat
…& then, use a couple of "tower mounts" up front :2guns:
 

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Flyinhillbilly

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I’ve got some race karts if you want to see how competitive it is ;)



Seriously though, if you need some measurements, pictures, or any other references from any of my frames I’d be glad to get them for you, it’s awesome that you’re building your own. It may be a beast.

---------- Post added at 11:08 AM ---------- Previous post was at 10:44 AM ----------

Fwiw, this is my favorite racing related song of all time.
https://youtu.be/McW2NwWtR9E
 

Functional Artist

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I’ve got some race karts if you want to see how competitive it is ;)



Seriously though, if you need some measurements, pictures, or any other references from any of my frames I’d be glad to get them for you, it’s awesome that you’re building your own. It may be a beast.

---------- Post added at 11:08 AM ---------- Previous post was at 10:44 AM ----------

Fwiw, this is my favorite racing related song of all time.
https://youtu.be/McW2NwWtR9E

Thanks! :thumbsup:

Yup, sounds good :cheers2:

I hope it's competitive :cool:
...but, it's mainly a (prototype) "test kart"

Ok, I have a question :popcorn:

What is the reasoning for or the concept behind the "angled" rear cross member that's seen on many race kart chassis'?
 

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Functional Artist

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I got the roll bar/seat back welded on
…& made/installed some custom upper seat mounting brackets :thumbsup:
(used a 2' pipe & a BFH to install the "curve")

I installed a 5/16" nut, inside of the front "tower mounts' for boltin' the seat down
(you can see it thru the hole I used to "tack" 'er in there)
...before weldin' them together :cheers2:

I cut some 1/4" real tough/dense foam rubber "pads"
...for between the seat & the mounts :cool:

I also, cut some 1/8" plastic "washers"
...for between the seat & the bolt heads :2guns:
 

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Functional Artist

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Dang you work fast!! Nicely done !!! :wai::cheers2:

Thanks! :thumbsup:
When I get focused on a project...:lolgoku:
…& this one has me kinda excited :wai: (I can see lots of potential & fun) :cheers2:

I'm gonna test 'er with a single motor &/or dual motors
...48V 1,000W or 60V 2,000W or 72V 3,000W motor(s)
...side mounted or rear mounted batteries
...72T (7.2:1) or 60T (6:1) or 54T (5.4:1) axle sprocket's
…& maybe even 10" or 13" or 15" rear tires :2guns:

Plus, remember what that girl in the movie said:
"Slow is ugly
…& this ain't ugly" :cool:
 

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I got the lower seat brackets welded on
…& then, bolted the seat down (with rubber pads & plastic washers)

Nice-n-solid
…& clears everything well :thumbsup:

So now, that we know where the drivers gonna sit, we can work on the steering system :cheers2:

For this we gotta keep (3) different things in mind
…& hopefully get 'em ta work together ;)

1. Steering wheel: placement, height, distance from seat

2. Upper steering shaft mount: lower connection (frame), upper connection (steering shaft)

3. Lower steering shaft mount: lower connection (frame), upper connection (steering shaft)

I started off with drillin' a 5/8" hole (on an angle) into the board, that the karts sittin' on
…& stuck a piece of 5/8" rod thru (with steering wheel) :2guns:
 

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Flyinhillbilly

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Thanks! :thumbsup:

Yup, sounds good :cheers2:

I hope it's competitive :cool:
...but, it's mainly a (prototype) "test kart"

Ok, I have a question :popcorn:

What is the reasoning for or the concept behind the "angled" rear cross member that's seen on many race kart chassis'?
I believe it’s to allow more chassis flex for more grip. Glexis a big part of handling on race karts. We spend a lot of time making sure that nerf bars, seats, and bumpers fit without binding since that affects flex and handling.

I was joking about the competitive thing, I think it’s cool that you’re building one of these yourself.
 
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