2020 - Excalibur Electric Racing kart

Functional Artist

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Cleaned 'em up a bit more :thumbsup:
…then, "test fit" 'em
...& added the third hole :cheers2:

Used (2) 5/16" x 1" bolts to attach 'em
...but, they can easily be welded together too :cool:

Super simple
...but, still good-n-strong :2guns:
 

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Flyinhillbilly

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Our race karts have oversized brackets for the spindles with washers stacked to take up the slack. We can move washers from the the bottom to the top or vice versa to set our weight distribution. I don’t know if you’re getting that serious with it, but I thought I’d mention it.
 

Flyinhillbilly

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If you need any othe angles it measurements just let me know.
 

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Functional Artist

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Our race karts have oversized brackets for the spindles with washers stacked to take up the slack. We can move washers from the the bottom to the top or vice versa to set our weight distribution. I don’t know if you’re getting that serious with it, but I thought I’d mention it.

Well, I already have the "stock" spindle brackets welded on :thumbsup:
...but, I could "whittle" 'em down (the spindles themselves)
…& then, add some washers, to shift things around a bit, "if necessary"

Thanks, for the motor mount pics :cheers2:

Yup, that's kinda like what I had in mind ;)

I'm thinkin', maybe I can even simplify on the design/construction a bit :2guns:
 

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Tie rod ends arrived yesterday :thumbsup:

Put 'em on
...then, measured, cut & threaded a couple of pieces of 5/16" rod :cheers2:

I used a piece of rod to double check the Ackermann
…& then, as a "guide" to help align the spindles :cool:

Now, that the steering linkage is aligned
...we know (for sure) where the steering shaft "arm" should be placed :2guns:

Looks like my initial marks were a bit off :huh:

Not, no more :sifone:
 

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Functional Artist

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Now that I know (for sure) where the steering "arm" should be on the shaft
...I took 'er apart (removed from the kart)
...put 'er on a bench (for a nice flat surface)
...aligned the "arm" with the steering wheel (so there 100% "true")
…covered/protected everything (that may be exposed to the "spatter")
...& weld 'er on good-n-solid :thumbsup:

* Also, before welding, I inserted a (appropriate thickness) piece of wood in between the "arms"
...to help maintain the proper distance (during welding)
…& to help keep the "spatter" out too :cheers2:

I ran a "bead" along the inside of each "arm"
...then, cleaned 'er up a bit
…& finally, ran another "nice" bead across both of 'em (it ain't goin nowhere) :cool:

* I only welded "in between" the "arms" (for a cleaner look) :idea2:
...not bad for a 90A HF "spatter box" :2guns:
 

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Functional Artist

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Oops :censored:
...I forgot some stuff :mad2:

Before, steering shaft final assembly & welding
...I measured, marked, cut & installed a "sleeve" for in between the steering wheel hub & the upper mount :thumbsup:

Currently the steering shaft is to be "secured" in place with "pins" above & below the lower mount
…& this "sleeve" will help "spread", any downward pressure applied on/to the steering wheel, across both mounts :cool:

* Also, forgot to mention, earlier that the "issues" with the end of the steering shaft "hanging" too low was that
...this chassis is gonna "ride" really low to the ground so, scrapin' would be annoying
…but, even more dangerous was, "if" the end of the shaft was to hit/catch on something solid, it could potentially "launch" the shaft directly toward the driver (me) :mad:

So, that's why it was not an acceptable situation :cheers2:

** Since the shaft is now pretty much done
...I went ahead & cleaned 'er up
...& then, sealed 'er up

I used a "bread tie" to prop the "sleeve" & bushing up "out of the way"
…& painted the shaft, underneath where the "sleeve" goes first

Waited a couple of hours
…slid "em down into place
…& finally, gave the whole thing a nice coat (satin black) :2guns:
 

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Functional Artist

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Sliding Motor Mount

The motor mount on an average electric powered kart is usually a piece of ~5" x 6" x 10g. steel
...with (4) slots cut into it for chain adjustment
…& then, it's just welded to a frame rail :cheers2:

I noticed that many racing style karts have/use a motor mount that "mounts" to/across (2) frame rails
...& also has the ability to "slide" on them rails, for chain adjustment
(dual purpose) :thumbsup:

* This set up would also allow for "quick-n-easy" motor swaps :cool:

Now, thanks to FH we got some pics :wai:

So then, I used this "info" as an example to design a DIY "sliding motor mount" for our electric kart :2guns:

The first idea was to use (4) "half moon" pieces, under a piece of steel to
...align the mount with
...allow the mount to "slide" along
...& also, to grip onto the frame rails

But, that had a lot (5 pieces) of "moving parts" to align & deal with :huh:

So, plan B was to simply use (2) longer "half moon" pieces
…under a piece of steel (only 3 pieces total) :sifone:

* Another issue that needed to be addressed
...was that the bolt holes on the bottom of the motor, were right above where the "slides" sit on the frame rails.
So, part of plan B was to "shift" the motor over a bit
…& use a bigger/longer plate.

This way the "slides" could be attached to the "plate"
...without interfering with mounting the motor to the plate. ;)
 

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Functional Artist

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I cleaned everything up & aligned everything on the kart for welding :thumbsup:
...but then, thought about the "spatter mess" :ack2:

So, I :idea2: made up a "welding bracket" out of some (4) scrap pieces of pipe :cheers2:

OK now, we kinda know where the "alignment" pieces need to be attached to the "plate"
...but, being "off of the kart" we need to be sure the "base" (slides), are "square" with the "top" (plate)

To do this, I squared (1) "alignment" piece, on the plate
…lined up with the "mark"
…& then, welded 'er on

* I noticed/ran into a weird thing
...some of the weld "puddle" seemed to "seep thru" the pipe :smiley_omg:
…& so, I had ta clean 'er up with a Dremel, before proceeding :huh:

Then, I could simply set the pieces on the "welding bracket", to weld the other "slide" :cool:
...at this point it's, basically, self aligning :2guns:
(& I'll also, "lighten up" or maybe, speed up on the weldin', for this side)
 

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Functional Artist

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I got the second "slide" welded on
…cleaned 'er up a bit
…& then, tried 'er on the kart :cheers2:

Wow! I really like it
...short, sweet & right to the point
…& she slides beautifully too :thumbsup:

After sitting the motor "in place", I noticed that there's an awful lot of unnecessary steel :huh:
(under/behind the motor)

So, I thought, :idea2: how about, maybe, lightening 'er up some
…with some "stylish" holes :2guns:

* They may even help with "air flow" around the motor :cool:
 

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Functional Artist

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Studding the pics from FH
...it looks like these type mounts use a "clamping action", for securing the mount to the frame :thumbsup:

I notice that on that mount (1) side is machined to "fit" on/around a frame rail
…& the other side seems to be more "universal" (just flat)
...but, it still "grips" on that frame rail too
(probably to fit on many different chassis) :cheers2:

My electric motor mount has (6) bolt holes

The (2) on the left (outside of the frame rails) are for connecting (1) side of the motor, to the mount

The (2) in the middle, are for connecting the other side of the motor to the mount
...& also, for connecting/securing the mount to the frame too

The (2) on the right, secure the mount to the other frame rail ;)

For the bottom side, Ima gonna use (2) pieces, of 1" U-shaped steel as "cross bars" :cool:

I was gonna add (4) "half moon" pieces to the "cross bars"
...but then, it didn't really seem all of that necessary :huh:

The "top" sliders should provide "all" of the alignment that we'll ever need
…& the "cross bars" should provide plenty of "grip", from down below, on the frame rails :2guns:
 

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Functional Artist

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While workin' on the motor mount, my "left brain" was already workin' on a "simpler/lighter" version :thumbsup:

So, I cleaned this one up a bit more
...wiped 'er down good
…& sealed 'er up (satin black)
(welding bracket too) :cool:

For version 2 Ima gonna try an 1/8" thick "plate"
...with thinner walled (14g. or ~1/16") "runners"

* The first one has a 10g. (almost 3/16") "plate"
…& uses 1/8" walled "pipe" for "runners"

This one will have the same "mounting" holes (for the motor & the clamps)
...but, Ima gonna add a different set of "aesthetic" holes
…& also, gonna try "plug welds" (from the top side) to attach the "runners" to the "plate" :2guns:

Last pic:
version 1 (on top)
version 2 below (both sittin' on the welding bracket) :cheers2:
 

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Functional Artist

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Sliding Motor Mount Version 2

By sitting Version 1 on the welding bracket, I could use it to
..."align" the (2) mounts (where they will sit on the frame rails)
…& also, to "square" 'em too :thumbsup:

I used (2) U-channel "lower" brackets, to secure the mount to the welding bracket :cheers2:

The "plug weld holes" are drilled out to 3/8"
...this way, I could get decent access to the "slides"
…to be able to apply a good size "plug weld" :cool:

I welded the "outer/perimeter" holes first (to help avoid warping)
…& then, welded the "inner" holes

* Notice the "bluing" on the "slides"
...seems like we got some "good" weld penetration ;)
 

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Functional Artist

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Yup, I think we got some "good penetration" :wai:

Next, I had ta grind a lot of the weld "build up" off of where the motor sits
...so, it can sit nice-n-flat, on the "plate" :thumbsup:

I left most of the "build up" on the "inner side"
...as there aren't any motor clearance issues on this side :cheers2:

Then, tried 'er on the kart
...slides like its on "rails" :2guns:
...but, ya can't even think about tryin' to twist-or-turn 'er :cool:

* Version 2 is much lighter
…& has a cleaner look too :sifone:
 

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Functional Artist

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A quick clean up
…& she was ready to be sealed up :thumbsup:

I "shot" Version 2 with some chrome/silver (so I/we can easily tell the difference between 1 & 2) :cool:
…& also, the "bottom" brackets too :cheers2:

As these (Ima gonna call 'em) "clamp" brackets are to be pretty much universal
...I went ahead & sealed up all (4) brackets (2 for each mount) while I was at it :2guns:

* Check out the reflection (of the "half moon's on the "plate") in the last pic :sifone:
 

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Functional Artist

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Looking great btw! I wish I had a fraction of the time you seem to so I could make a little weekly progress!

Thanks! :thumbsup:
I'm a tow truck driver
...so, I'm always "on call" (have to be "ready & available")
...but, if the phone don't ring (I got time to do "my stuff")
...& with all of this "crazy" stuff goin on (everybody staying home & many repair shops closed)
...I got some extra time :wai:

* Sometimes ya just get "on a roll" (had a lot of ideas flowing lately)
…or "on the Jazz" as Hannibal (from the A-Team) would say :2guns:

Your makin' good progress, just stick with it :cheers2:

** I try to "plan when I can" (like when drinkin' coffee in the morning)
…& then, "work the plan" when I have time (usually in the eve, after the kids go to bed) :cool:


*** Um...maybe a new "signature phrase"
...yours doesn't exactly SCREAM motivation (just sayin') :lolgoku:
 

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Designers note

Design note:
I designed this frame with "dual" frame rails in the rear, on both sides.
(where as most racing style frames just double 'em up the engine side)

This dual frame rails concept was "dual purpose" :cheers2:
...for the ability to mount (2) motor(s) (1 on each side)
…& also, for use as battery trays (2 on each side)

The motors are to be bolted to their mounts
...which are then, aligned, adjusted, supported & secured by/across (2) frame rails
…& the (2) batteries are to sit, just ahead of (a) motor (in a shallow tray) & be supported by (2) frame rails


The way I designed the mount, the motors bolt holes influenced/dictated where/how the motor was attached to the mount
…& also, where the mount was to be placed onto the frame
…& then, the right motor's placement kinda dictated where the driven sprocket needed to be aligned, on the axle

The left motor can/will use the same mount
...as it's sprocket, is easily adjustable :cool:



So, I mounted a 48V 1,000W MY-1020 motor on to a motor mount (version 1)
…& then, sat 'er on the kart frame, to align the drive sprocket with the driven sprocket :thumbsup:
(I used a straight edge to get 'er nice-n-true)

With this measurement, I was able cut a "spacer", for in-between the bearing & sprocket (see 3rd pic)
…& then, another "spacer" for in-between the sprocket & the rim (see 4th & 5th pics) :2guns:

Once the sprocket was "in place", I measured, made up & installed a chain
(using the 60T sprocket (6:1) for our first test) :D
 

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