Building a go kart size Aerial Atom

[Functional Artist]

Can't do some stuff before we do other stuff

I don't want to
...weld in the "dash bar" until I have the floor pan in to ensure proper clearance.
(gotta be sure that we have enough space between the operator & the bottom of the steering wheel.

...weld the foot board on until I have the steering shaft trajectory established
(gotta be sure the steering shaft lines up with the bushing brackets)

...weld the spindles to the ends of the A-frames
(gotta be sure the tie-rods will line up & clear)

 

[Functional Artist]

So, I guess a floor board is next on the agenda.

But, not just a plain floor board, I'm thinkin' that's where the battery is gonna reside on this one.

This way it'll center the added weight of the battery pack (~50 lbs.)
...& also spread it out a bit more. (10 lbs., 10 lbs., 10 lbs., 10 lbs. & 10 lbs.)

There looks to be enough room for a seat in the space between the barrery pack & the seat back (~10")
...but, the space from the steering wheel to the battery pack looks minimal (3 1/2")

 

[Functional Artist]

Maybe we can drop them batteries down, like in a tray
…& (maybe) bring the sides up ~45* to meet up with the bottom of the "rib rails", on each side.

In this scenario, the floor board would be ~12" wide with a ~6" wide tray down the middle that was ~2" deep.

It should be plenty strong & give more clearance between the steering wheel & battery pack, but would be hard to make & not much room for the operators feet. (even with the first battery turned sideways)


So, rethinkin' it
...maybe we should drop the whole floor board ~2" & go with ~14" wide (~max width @ the foot/front suspension board)

It would lower the center of gravity & provide more foot room

 

[Functional Artist]

Still playin' with different battery arrangements

Yup, I think we can make it work

 

[sikbrik]

Funcionally, and aesthetically, I like the setup with all 5 down the middle, side by side, from seat to steering.

My fear is that this limits you to that size of battery...do you think you'll ever want anything with a bigger footprint or taller height? If not, that might be the way to go.

I guess in reality, when people upgrade batteries, they go smaller (lithium) rather than larger SLAs anymore.

 

[itsid]

While I like the setup..
I just want to make you think about this:
"tight cage, someone's crotch trapped close to the burning/leaking batpack..."

How fast do you think you can get out of that thing when panicking?

So yeah.. looks good, nice CoG... is it worth it?
IDK.. I'd ride that, but I'd certainly not allow my kids to ride it let's say

'sid

 

[Functional Artist]

While I like the setup..
I just want to make you think about this:
"tight cage, someone's crotch trapped close to the burning/leaking batpack..."

How fast do you think you can get out of that thing when panicking?

So yeah.. looks good, nice CoG... is it worth it?
IDK.. I'd ride that, but I'd certainly not allow my kids to ride it let's say

'sid

Hey Sid,
Always appreciate your input.

Yup, thought about it & definitely keeping it in mind.

For this one I'm thinkin' a full length formed battery box/cover would be a good idea.

Probably plastic (non conductive) or possibly metal (if necessary)

Kinda like a console that would protect the batt pack, the connections & even the cables & wires.

Maybe even mount the circuit breaker to it.

That way it would be close @ hand & even closer to the bat pack.

 

[Kartorbust]

What about metal on the bottom and sides, plastic for the cover?

 

[LawnCrawler]

a panel of G-10 would make a nice firewall/cover for your battery box. it is fairly lightweight, non-conductive, fireproof, chemical resistant and pretty cheap compared to any similar composite.
You can cut it on a table saw and rivet and/or bond it to 1/2 alum angle stock to form super strong corners.

 

[Functional Artist]

Good suggestions fellas, we'll cover 'em when the time comes

Gotta get a floor pan in 'er next.

I picked up a piece of expanded steel & cut it into (3) 32" x 48" pieces.

I'll use (1) piece for this kart & save the others for future projects.

So, the floor is to be ~14" wide, down the center, with both sides bent upwards @ ~40* angles.

@ 48" long it's a bit too long to use my bench for bending so, I clamped it down @ the 9" mark, to the back of my truck, bent it ~ 40* then, spun it around
...& clamped 'er down @ 9" again & bent that side to ~40* too.

Sorry, no pics today
...my camera died ('er the battery took a shirt)

 

[Kartorbust]

Do you not have a smart phone with a camera?

 

[Functional Artist]

Do you not have a smart phone with a camera?

Nope, I still got a "flip phone"
...rockin' it "Old School Style"

But, I ordered a new battery (~$10.00 delivered)
...it should be here in a few days.


*Side Note

The "Devil is in the Details"

Ya, gotta check the specs

When looking for a new camera battery I found, several that claimed to be interchangeable with mine but, when I checked the specs, some the numbers were "way" different (mA & such)
...I'd rather have an OEM replacement (the exact same battery)

And I noticed that there were a lot of "used battery's" available (~$7.00)
...Really?

This little battery is only ~$10.00, I don't see why I (or anyone) would bother with a used one

 

[Functional Artist]

Workin' on a dash/steering support bar

So, I've been bendin' some pipe

I made up (3) different options (so far)
...but, ya can't see 'em yet

Still waitin' on the camera battery

 

[Functional Artist]

"Back in Business" (got my new camera battery)

Now for dash bar options

First, I tried a simple pointed arch (kinda like in the drawings) but, there was only ~8" between the bottom of the steering wheel & the floor & only ~11" of (knee room) on each side of the steering

Then I thought, how about a "raised" dash bar, which brought the steering wheel up a bit (~9") & the knee area up too (~13")
...but, it wasn't super stylish

I got a couple more ideas & pics

Spoiler Alert:
Don't look at the other dash bars on the stool

 

[Functional Artist]

I ain't lookin' to be bangin' my knees on a steel pipe

So, then I was thinkin' "knee bumps", let's get creative & make a bar with some bulges or bumps to give us some knee room.

My first attempt had good clearance (~9' @ the steering wheel & ~ 13 1/2" @ the knees)
...but, it just looked IDK ...like too much ...like "overbearing" even

So, lets try this again, maybe a bit mellower this time

To make 'er, I used a 36" piece of pipe, marked in the middle & also @ 10" from each ends.

It took 60 pumps @ both 10" marks (makin' sure to keep 'em nice-n-straight & in alignment)

Then, flipped the pipe 180* & bent 'er right in the middle (~50 pumps)

Yup, I like it

I think we'll roll with #4

 

[Functional Artist]

A couple more pics

My knees are actually ~4" behind the dash bar
...& there looks to be ~3" between the "knee bumps" & my knees

Should be plenty of room, to keep from bangin' my knees while bouncin' around a bit

 

[sikbrik]

I kinda like the one on the beginning of your second set...it has the v notch in the middle but some vertical at the outside ends. Or is it just perspective? Looks a little more forgiving than the final bar and has some symmetry to match your frame style.

Awesome work so far!

 

[Functional Artist]

I went with dash bar #4 (I thought about #3 again but, it was just too much) & got 'er welded in

Then, aligned the steering shaft & welded the bushing holders, for it, in too.

After it kooled down, I inserted the bushings & slid the steering shaft in.

Works nice-n-smooth & has ~16" between the seat back & the steering wheel.

 

[Functional Artist]

Next, I made up a 6" x 19 3/4" battery tray out of 1" angle steel (to hold (5) 12V 12AH SLA's) & sat it under the steering wheel, on the floor of the kart.

Well, Sid was right about the space in the foot area being "tight"
(but, I think I found a "happy medium")
…& then, right again about putting the battery pack on the floor board

I like the idea (it would improve the balance & COG a lot) but, it just ain't workin' out on this kart.
…& with the foot area already being kinda "tight", puttin' the battery pack there takes up too much room & totally changes the equation.

 

[Functional Artist]

Battery tray plan B

They seem to fit nicely right behind the seat back, where the lower "rib rail" flattens out

Yup, that looks good-n-solid & will help keepin' the wires (battery cables) short
…& we gots lots of foot room now