Desteny's "Cotton Candy" kart

[Functional Artist]

My twins, Desteny & Winston, are out growing their karts

So, I'm thinkin,

Desteny can "move up" to "Cotton Candy" (that's what she wants to call 'er)
...it started off (2016) as "Double Trouble" (2) (24V 450W motors) https://www.youtube.com/watch?v=TRIKLdvGlTA

...& then (2017) was known as El Turbo (1) 24V 450W motor with an "overvolt switch" that would "temporarily boost" 'er up to 36V

https://www.youtube.com/watch?v=H-704ZyJkaU

& Winston can "move up" to Desteny's kart

https://www.youtube.com/watch?v=apJH3f1YBZM

 

[bob58o]

So what do you do with the little orange one now?

 

[landuse]

Kids grow up so fast

 

[Functional Artist]

So what do you do with the little orange one now?

Modify it
V8 Chevy w/slicks & headers

IDK ...maybe sell it

I could use the room
...& my project fund is getting super low (empty)

 

[Functional Artist]

So, this kart needs (a little TLC)
...a motor, controller, on/off switch, circuit breaker, charge port & (4) batteries

I got a 48V 1,000W motor kit from Alfa Wheels (~$100.00)
(off of the !Arriba! kart)
...& (4) 12V 17AH SLA batteries
(I had 'em on the shelf, I used then on El Dingo II last summer)

Motor: 48V 1,000W ZY-1020
Speed Controller: 48V 1,000W YK-31
On/off switch: key switch
Circuit Breaker: 50A
Charge port: PC style

I'll start with installing the motor

Over/under or Under/over

 

[Functional Artist]

Motor's on...Check

Now, for the other stuff

Let's get creative

I think, I'ma gonna mount the key switch (on/off)
...circuit breaker
...& charge port in one of those kool plastic "drill bit boxes"

Kinda like an enclosed "dash"
…mounted onto the steering support
...easily reachable
...under the steering wheel
...right in front of the operator (my little Desteny)

Layed out, measured, marked, drilled, cut/check, cut/check, cut/check

 

[Functional Artist]

Hmmmm, should it go
…@ the bottom?
...in the middle?
...or right under the steering wheel?

Right under the wheel is the winner
...just gotta remove the (2) switches
…& bolt 'er down
(even using the holes that are in the existing bracket)

Since it's just a plastic box, I used big washers under the bolt heads (inside the box)
…& made a "doublewide/plastic" washer (for the back side)
...to spread out the pressure

Yup, nice-n-solid
...that'll work

 

[Functional Artist]

Kids grow up so fast

Yes they do.

First (2) picks are from back in 2014
...purple kart, is the first kart I made for them
...orange kart is Winston's kart

Third & fourth pics (~2015) are of Desteny's kart (before paint)

Last pic is Desteny's kart (after paint)

Wow, "memory lane"
...their getting so big (i'm about to cry)

 

[Functional Artist]

Speed controller is next
...but, ...where to put it?

Hmmm...
...batteries will be behind ya
...motor is mounted under the seat
...dash is right up under the steering

I had the previous (24V 500W) speed controller
...mounted under the seat (right next to the motor)
...but, the connections/plugs & wiring were all right out in the open & exposed

I would like to put the connections in a box (kinda like I did on the Torsk)
...to protect them from damage (physical &/or water/corrosion)

How about, right on the kart floor
...behind the steering support
...directly below the dash

Ya, that might work

I got a couple of these kool black plastic boxes
(different project/different story)

I figured, maybe
...mount the speed controller to the top of the box
...route the wires thru a hole
...& make/keep the connections inside

 

[lliberto]

Sweet

Sweet

 

[Functional Artist]

Yup, I like it

But, what about kooling?

Speed controllers get hot

It's gonna be right out in the open
…& has "mini" kooling fins on the case

They are usually (or recommended to be) mounted to a flat (preferably metal) surface
(to act as a "heat sink" & help draw some of the heat out of the controller)

So, since it's gonna be mounted to a plastic box
...we should probably add a heat sink

I'm imagining a controller with "wings"
...lets make a "homemade" heat sink

Cut a piece of aluminum (out of an old sign)
...screwed it to a wooden piece of 2" x 4"
…& did some body work

Yea,
...that should help "wick" some heat away

Looks kool & functional... "Functional Art"

 

[Functional Artist]

Lets stack 'em up

Speed controller, on top
…"winged" heat sink, in between
…& plastic box, on the bottom
(conveniently, with "feet" for mounting to the kart)

 

[Functional Artist]

I simply set the speed controller assembly under the steering support & bolted 'er down
...using a "big" plastic "washer" (pressure spreader) under the kart

It's centrally located, will get plenty of "air", is out of the way & safely protect the plugs/connections

The "best" part is that the top of the box, with speed controller attached, flips open for easy access to the connections

 

[Functional Artist]

Now we gotta connect everything up

Motor is close enough to "plug right in"
Throttle & brake wires were long enough too
Key switch just needed (2) wires to connecting it
Charge port positive (+) connects to the circuit breaker, inside of the dash box
...& the negative (-) connects to the speed controller negative (-), inside of the black box
Battery connections were last
...the positive (+) runs thru the circuit breaker first, then to the battery pack positive (+)
...the negative (-) runs straight to the battery pack negative (-)

 

[Functional Artist]

The "Power Pack" is last

The battery box was originally designed to fit (4) 12V 35AH SLA batteries (~20 lbs. ea./~80 lbs. total) snuggly

Since I've come to the conclusion that its "stupid" to carry around all of that weight
(all of that added weight affects top speed & maneuverability dramatically)
...but, is also a PITA to move around & deal with while in storage

The (4) 12V 17AH SLA batteries (~10 lbs. ea./~40 lbs. total) that we are gonna use, are a lot smaller & lighter (& I already had 'em so, lets put 'em to use)

Smaller batteries means that we will have lots of extra space/room in the battery box

We need a way to hold 'em in place (so, they don't slide around in the box)
…& strap them down (so, they don't bounce around)

Hmmm....

We can slide 'em (the batteries) all of the way forward
…& use a ~2" wide strap (with a nice little latch) to "strap 'em down" (help hold them in place)

Then, install a 1/4" bar/rod across the back side (to keep 'em from sliding back)

*to install the strap, I had to add a 'slot' for the strap to go thru
...marked the spot, drilled a couple of "guide holes". used an angle grinder to "cut the slot" & cleaned 'er up with a Dremel

 

[Functional Artist]

I got the (4) batteries strapped in "good-n-tight"

Time for a test ride (to make sure it's safe)
...before I let my Desteny take 'er for a spin

https://www.youtube.com/watch?v=DXqjIvRQg-Q

 

[Functional Artist]

Yup!, she rolls out nicely
…& moves right along with the 48V 1,000W motor

So, me & Desteny took a ride
…& she did real good

https://www.youtube.com/watch?v=oAq-hHib3fM