2020 - Excalibur Electric Racing kart

[landuse]

Excellent work!! You are SO close

 

[Functional Artist]

Thanks fellas!

Sat 'er on the ground
…& installed the wheels

Boom!
...we have a "roller"

Ima gettin' excited

I can (almost) feel the "wind in my hair" already

 

[Functional Artist]

I started wiring up the batteries
...using the same red 10g. wire that I used for wiring the CB

* Most wire has an inherent resistance, in the material their made from, to the "energy" flowing thru 'em
...as such, the longer a "wire" is, the more resistance it has

So, the "cables" used for connecting batteries "in series" should all be of the same length
...this way the "energy" flows thru 'em all consistently (no "bottle necks" so to speak)

But, this presents a problem

We have (2) batteries next to each other, on (1) side of the kart
…& the other (2) batteries, next to each other, on the other side of the kart

So we need a short cable (~6") connecting (2) batteries
...a longer cable (~20") to cross over to the other side
...& another short cable (~6") connecting the other (2) batteries

I would think, the proper solution would be to make all (3) "cables" (~20")
...but, that seems like a lot of extra/unnecessary wire

So, Im thinkin' I'll try (2) 10" cables & (1) 20"

Where is my buddy Sid?
...he would have some input on this situation

** Also, when workin' with higher voltages it's best to use insulated tools

I went to use a flat head screw driver to bump/coax a Spade terminal on to it's terminal
…& accidentally "shorted" (2) battery terminals

The screw driver, the terminal & my finger all "took a hit"
*** Note to self, DON'T do that again

 

[Functional Artist]

Here is a short video, to visually document the build, so far

I did a quick "first system check" too
https://www.youtube.com/watch?v=ylwN3lNoTJU

 

[Functional Artist]

A couple of days ago, I gave the floor board a chrome "look" (chrome spray paint)
...but, it really looks more like polished aluminum

So, now it's ready to install
…& the seat too

 

[Functional Artist]

Maiden Voyage

I took 'er out for a Maiden Voyage (first test ride)
...but, Ima not gonna say no more

Um, yup
...we have a video

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

Let me know what you'all think

 

[Functional Artist]

I made up some straps to secure the batteries

The black one is from a kids car seat
...but, the buckle didn't seem too strong

The yellow one is made from "ratchet strap" material
...but, the "cam action buckle" didn't "grip" too good
...so, I tried/added a different buckle

* I'm tryin' (2) different type straps & buckles, as a test
...just to see how well they will work
...& also, how long they will last

** I also wired up the reverse switch

 

[Karts of Kaos]

looks pretty Skippy. do you know if it is track legal?

 

[Functional Artist]

looks pretty Skippy. do you know if it is track legal?

IDK
...what's the "rules of the track"?

Uh...paging Flyin' Hillbilly
...we got more questions

 

[Brianator]

Right arm! Not only does it look good but it looks like it's working good too! How fast do you figure you got going?

 

[landuse]

I took 'er out for a Maiden Voyage (first test ride)
...but, Ima not gonna say no more

Um, yup
...we have a video

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

Let me know what you'all think

Cool beans!!! That was an awesome test drive. It looked like everything worked the way you hoped it would. Another excellent build

looks pretty Skippy. do you know if it is track legal?

If there was a class for electric karts, I am sure it would probably be legal

 

[Functional Artist]

Right arm! Not only does it look good but it looks like it's working good too! How fast do you figure you got going?

Thanks!

Yup, everything seems to be "operating within specified parameters"

Not sure
...speed tests are comin' up

 

[Bansil]

sweeeet

 

[Functional Artist]

Next, I want to install a meter to monitor the energy level in the battery
…& also, the power usage

A PZEM-051 should do the trick
(more info)
http://www.diygokarts.com/vb/showthread.php?t=42102

It displays the Voltage (V) of the Battery pack
...the Current (A) Amps being drawn from the battery
...the Power (W) Wattage of the component drawing power
…& (records) the Energy used in (Wh)

* I believe the Wh (Watt-hour) "function" displays the energy that's already been used, out of the pack
…which should help us calculate the "available" energy, that's still left in the pack

I've been thinkin' about where & how, to mount the meter

It's gotta be easily visible
...but, also not "obtrusive" or in the way

Was gonna use the upper steering bushing mount bolts to attach a bracket, that would hold the meter, just in front of & above the steering wheel
...but, it's gotta be in some kind of a container
…it's gotta look kool too

Sooooooo, a "worn out" old pair of HF hearing protector/ear muffs "caught my eye"
…& I said, Hmmmmm

I dismantled the "muffs"
…just "stuffed" the meter into (1) of the rubber ear "pads"
…& then, "stretched" the "pad" back onto the (red) outer housing

The meter, in it's new housing, mounted easily on to the "headband"
...but, it wasn't very sturdy (kinda "floppy")

Then I thought, why not just mount 'er right on the steering wheel
...that should be pretty sturdy
…& also, easily visible

 

[Karts of Kaos]

If there was a class for electric karts, I am sure it would probably be legal.

I meant the frame. I did not know if you were allowed to build a frame or if you have to buy it.

 

[Functional Artist]

I meant the frame. I did not know if you were allowed to build a frame or if you have to buy it.

Hmmm, that's a good question

I figured there were height, width, length & weight requirements/restrictions
...but, I never thought about "if" the frame needed to be professionally designed &/or manufactured

* Hopefully FH will "chime in" with some info
...he knows about this stuff

 

[Functional Artist]

I used the "upper" of the (3) steering wheel mounting bolts, to mount the meter housing

Then, to wire up the meter, I first drilled a 3/8" hole
…added a rubber grommet
…& then, "run" the (3) wires thru

The red wire (B+) supplies the voltage info to the meter
…& powers the meter too

* The voltage indicator wire on this SC is "switched" (which means that it's turned on/off with/when the SC is "switched" on or off)

The black wire (B-) supplies the negative (-) info, to the meter
…& also, completes the circuit, for "powering" the meter

The yellow wire (P-) supplies the "differential signal" (amp draw) to the meter

 

[gegcorp2012]

Looks cool.

It was nice to see it zipping around the side streets. Looks like you have a nice place to ride close by.

Sent from my SM-J700T using Tapatalk

 

[Functional Artist]

I "ran" into an issue

I turned the circuit breaker on
…& then, flipped the on/off switch to "on"

Then, I heard the speed controller "click on"
…& meter "lit up" too

But, when I looked at the meter,
...the voltage was only showing ~1/2 of the "actual voltage" of the battery pack

Well, thinkin' it thru, it seems that I forgot to install a "jumper wire"
...between the (2) negative (-) terminals

Yup, that's more better

 

[Functional Artist]

Took 'er for a ride
...to get some data, from our "new" meter

Here is some footage of the meter, during the ride

https://www.youtube.com/watch?v=KAQ0nAXr0cU

I accelerated from a "dead stop"
…& the first thing that I noticed was the huge voltage drop (almost 6V) on "take off"

The next thing that I noticed was the Wattage, which showed ~ 1,720W
...the Max Wattage, that I saw (from this 1,000W motor) during this ride was ~1,760

The Amperage showed ~37.69A
…& the Max Amperage was 38.26A

At the end of this "test ride" the meter showed the voltage level, down to 48.9V
…& that I had used ~190Wh of energy, from the batt pack