Damien

[Functional Artist]

I think there is gonna be a change of plans
Santa brought ma a kool butterfly style steering wheel
It even has protrusions on top of each side, that are perfect for mounting a hand brake lever on the left side
...& a thumb throttle on the right

 

[Functional Artist]

I also picked up a splined hub for my new steering wheel but, (there is always a but) it's a bit too shallow (puts the steering wheel too far away, for comfort) & the shaft, I'm using, don't have splines anyways.

I'll use this hub as a template & make my own taller/extended hub

First, I marked which holes match up with the steering wheel.

I used a 1/8" thick x ~2 1/2" dia. washer, a 1/2" bolt & some electrical tape
(used as shim material to "build up" from the 1/2" bolt to the 5/8" splined center hole)
…clamped 'em together to drill some "marker" divots
…& then, took 'er apart to drill 'em out proper

 

[Functional Artist]

(1) custom made (taller) steering hub BOOM!

I squared up the Pitman Arm, slid the steering wheel/with hub on to the steering shaft, aligned it (by measuring the height on each side) & drilled some attachment holes

*gotta get some shorter steering wheel to hub bolts (maybe like some chrome Allen heads)

 

[Functional Artist]

I got an idea for a rear control box
…& I think it looks kool too

It's a 80's era hard cover plastic audio cassette carrying case
...about the size of a laptop case just a little thicker

I can mount the speed controller right on top (for good kooling)
…then, run the wires thru a hole & make the connections inside.

Inside there's plenty of room for all of the connecting plugs, a shunt (for the dash meter) & the fuse (or circuit breaker)

Should be mostly water resistant, will keep all of the connecting plugs safe & sound while allowing easy access, if/when necessary.

I think, it will look kool mounted behind the seat, right above the motor & batteries.

Repurposing at it's finest

 

[Functional Artist]

I picked up a piece of 1/2" x 1" x 1/8" x 36" steel channel to make a couple of control box mounting rails out of. ...& I got Damien out to do a "dry fit" of the control box & take some measurements for the mounting rails

Once I had that info, I measures, marked, cut the pieces of channel
...& then, shaped the ends to fit snuggly.

 

[Functional Artist]

After double checking the height, squareness (as opposed to the rear bar) & also making sure the rear control box would sit level, I welded the (2) support rails on good.

I just got & started using a welding apron to protect the tires from welding (heat, sparks, spatter etc.) & also to help reduce the "colleterial damage" clean up.

It seems that every time I add another piece to the puzzle (weld another piece on) it adds "so much" to the cleanup.
That sucks!, especially in them hard to reach places or places that I have already cleaned up (a few times)

Yea, that works SO MUCH BETTER!

 

[Functional Artist]

Pics of the control box

Kinda wanted to put 'er on an angle like the side rails
...but, it would have had to sit too far back to open properly.

I like it, it still looks kool!

Easy access & plenty of room

 

[landuse]

Looking good FA

 

[Functional Artist]

Winter has arrived
...with a vengeance

So I'm stuck doin' indoor projects
...well, I guess it's time to do the seat cover

I still have some of the black pinhole vinyl, left over from makin' the seat for the Atom kart
…& also some of the faux Crocodile material, left over from makin' the seat for the Torsk kart.

I'm thinkin' a black vinyl seat with a Crocodile insert.

I did some measurin', markin', cuttin' & sewin'

Then, I layed the seat back in place on the material, marked the outline & sewed on the side flaps.

Sewed up the corners, nice-n-square
…& then, curved 'em in a bit (to help it'll fit snuggly)

 

[voided]

Did you try the thumb throttle on the steering wheel yet?

Wondering if it fit or how close to fitting it is..

Was gonna do something similar, for my build..

 

[Functional Artist]

Did you try the thumb throttle on the steering wheel yet?

Wondering if it fit or how close to fitting it is..

Was gonna do something similar, for my build..

Yup, I tried 'em
The thumb throttle & brake lever fit nicely.

 

[voided]

I had a padded steering wheel I was willing to chop up, get to the metal and it was micro.. would of been a pain to build spacers for it. And the brake lever would also have to be modified...

Going the way you did looks great, functions and doesn’t need any modifications...

 

[Functional Artist]

To finish the seat bottom up, I sewed all (4) corners up nice-n-square
…rounded 'em inwards just a bit
…& then, flipped 'er right side out (with the seams back on the inside)

Next, I cut (2) pieces of 1" foam rubber padding, to match the plywood seat base
…tucked 'em into the seat cover
…& then, tucked the plywood base in.

Made sure it looked nice-n-straight from the top side
...& started stapling 'er down

A few staples on each side, kinda in the middle
…& then, workin' toward the corners.

Turned out pretty good!
...definitely not Bad!

 

[Functional Artist]

I got the seatback done too.
...same procedure

Boom! (1) black vinyl, low back bucket seat with a (faux) Crocodile insert
* I sat 'er on a kitchen chair to show how the dimensions compare.

 

[Functional Artist]

Worked on the control box a bit more

I marked & cut a template out of cardboard then used it to align & mark the spot for the cutout, for the circuit breaker.

Then, drilled holes at the corners & simply cut 'er out.

It wasn't quite that easy
...but, turned out pretty good.

 

[Functional Artist]

Now that the Circuit Breaker is "in place" next up is the charge port.

I am using XLR style DC output plugs for ALL of my 48V karts (with SLA battery packs)

A while back, when I WAS going to use C-13/C-14 style charger plugs/receptacles, I found these kool "covered" receptacles & thought that they would be a good way to keep the charge port terminals covered.

But, since I'm NOT gonna use them any longer I thought maybe I can still put 'em to good use.

So, I cut out a spot to mount it on the side of the control box.

Now, just gotta figure out/work on mounting an XLR receptacle inside of the covered C-14 receptacle.

 

[Functional Artist]

I removed the contact terminals for a "heat test" a few weeks ago.

Then, used the bench grinder to "smooth" the back side.

Yup, it looks like it will fit

Drilled a "pilot" hole in the middle
...& then, drilled 'er out to ~5/8"

 

[Functional Artist]

Slid it thru the front side & cinched 'er down with the nut from the back side.

Then, inserted it into the hole in the side of the control box.

Yup, we now have a "covered" XLR charge port/receptacle

The last (2) pics are with the charger plug attached

 

[Functional Artist]

Got a bit more done on the rear control box.

I was thinkin' it would be best to "beef up" the mounting area of the Circuit Breaker & Charge Port.

Mainly because both of them are only mounted in plastic & will be physically handled often
...switching the CB on/off
...& attaching/detaching the charge port.

So, I added some TV back panel plastic to stiffen the mounting pads for both components.
…& added some Allen head bolts with lock nuts.

 

[landuse]

Looking good