Just picked up a brand new Lighting Bug

[Bmr4Karts]

Don't have it too tight! There must be a slight amount of play in the chain. It mustn't be taught.

yeah, it's just right. Small amount of flex and tight enough to keep it from jumping teeth.

Next on the punch list is getting the throttle linkage buttoned up.

Currently the throttle cable does not have enough travel to match the travel range of the thumb throttle so I cannot get full speed using the go pedal.

They adapted the thumb throttle to this duty by just drilling a hole in the thumb area.

The throttle cable is made just like the other picture I've attached minus the 1/2" barrel near the top of the picture. In place of the barrel is the thumb throttle with the hole in it.

The other end of the cable goes into the throttle pedal.

To get more travel I'm thinking about adding a piece of metal to the side of the throttle pedal that will raise where the cable is attached making its travel longer as the pedal moves.

Also, does anyone know about shortening this type of cable? I think the outer casing is too longer versus the inner cable and that will also limit the travel range of the cable. I don't think I can reuse the fitting that was crimped on so I need to find/buy another one. I'm not sure what it is called.

I think I'll just put an actual electric throttle pedal in instead of fooling around with this linkage setup.

 

[Functional Artist]

It looks like you should be able to adjust the throttle (2) ways.

1.) There is a lot threads to adjust the throttle travel range right at the pedal.

2.) There should be an Allen head screw on the thumb throttle where you can adjust it's position too.

If you do end up needing to change the actual length of the cable, after cutting
...use a cable clamp, something like this:
https://www.ebay.com/itm/BIKE-ADJUS...m=122311421518&_trksid=p2047675.c100009.m1982

 

[Bmr4Karts]

It looks like you should be able to adjust the throttle (2) ways.

1.) There is a lot threads to adjust the throttle travel range right at the pedal.

2.) There should be an Allen head screw on the thumb throttle where you can adjust it's position too.

If you do end up needing to change the actual length of the cable, after cutting
...use a cable clamp, something like this:
https://www.ebay.com/itm/BIKE-ADJUS...m=122311421518&_trksid=p2047675.c100009.m1982

You were right. It took some trial and error but I was able to get the full range of throttle out of the stock pedal. I had to re-position the thumb throttle and few times and verify the actual range of travel of the thumb throttle (it's a lot less than the white lines/bars indicate). I used a digital tachometer to verify I'm reaching full speed versus the motor being powered directly by the batteries (200rpms).

So top speed should about ~7.5mph based on the 12.5" diameter of the rear tires.

Next up is speeding this guy up.

I want to use 3 18v power tool batteries in series and just need to know a couple things.

Can a 48v controller handle 56v? (probably closer to 63v when fully charged)

Can the my1016 36v 500w motor handle that voltage?

 

[Functional Artist]

Kool, glad it worked out for you.
...there's more than one way to "peel a potato"

Most of these small electric systems are (seem to be) based on the standard 12V lead chemistry ranges.

1 - 12V lead acid battery = ~13.3V fully charged
2 = 26.6V
3 = 39.9V
4 = 53.2V
5 = 66.6V

As you can see a 48V systems limit should be ~54V -55V
...so, IMO, 63V would be WAY too much for a 48V system to handle.

FYI/BEWARE, a 48V system can easily propel a small kart 20+MPH
...which doesn't seem like a lot, until you see your little girl fly by

 

[Bmr4Karts]

Kool, glad it worked out for you.
...there's more than one way to "peel a potato"

Most of these small electric systems are (seem to be) based on the standard 12V lead chemistry ranges.

1 - 12V lead acid battery = ~13.3V fully charged
2 = 26.6V
3 = 39.9V
4 = 53.2V
5 = 66.6V

As you can see a 48V systems limit should be ~54V -55V
...so, IMO, 63V would be WAY too much for a 48V system to handle.

FYI/BEWARE, a 48V system can easily propel a small kart 20+MPH
...which doesn't seem like a lot, until you see your little girl fly by

Alright, say I stick with 36v since it is a lot simpler power wise and I have several of these 18v tool batts.

Should I just get a 24v 350w my1016z3 motor and power it with 36v to get my top speed closer to 15mph?

I'm not sure what other options I have without the use of a jack shaft and there's not a lot of room for a large axle sprocket.

 

[Functional Artist]

Many/most of these DC motors can deliver ~70RPM per volt
...12V should be ~840RPM's
...24V = ~1,680RPM's
...36V = ~2,520Rpm's

So, maybe try using the "Ball Park Equation"
...just insert your numbers

MS/GR=ASxTC=IM/FT=FMxHR=FHxMM= MPH

Motor Speed/Gear Ratio=Axle Speed x Tire Circumference = Inches per Minute traveled/Foot(12) = Feet per Minute traveled x Hour(60) = Feet per Hour traveled x MPH Multiplier(.000189) = Miles Per Hour

http://www.diygokarts.com/vb/showthread.php?t=38785&highlight=ball+park+equation

This should help you with your figuring/planning.

 

[Functional Artist]

This thread has lots of info & testing that you may be interested in & help in making upgrade decisions.

http://www.diygokarts.com/vb/showthread.php?t=37442

Most tool batteries (I've seen) are only ~1AH -3AH which would probably only last ~10 min. - 15 min. powering a kart.

If/when you upgrade maybe look into a 48V Boma style motor.
https://www.ebay.com/itm/1500W-Watt...Jb6kfj:sc:USPSPriorityFlatRateBox!43607!US!-1

It is brushless (no brushes to wear out), reversible (at the flip of a switch) & has a (3) speed function
...you can start her off in low, then move up to med & then, high as her skills advance.

 

[Bmr4Karts]

Funny you should post now. I just finished testing out bumped up voltages less than 5 mins ago.

I started with my standard 40v and kept adding RC lipos until I got up to 53v (14s not fully charged) Motor cool, esc cool, even with my 200lb frame. So my plan is to keep adding volts until the esc blows then I'll just buy a higher voltage one.

The 350w motor still does not have the torque to get me up a hill but this car is for my 35lb daughter, not me so that's not a problem.

My power tool batteries are 4AH and I can fit 6 of them making a 60v 8AH power supply (I've got at least 10 of them). Next time the Ryobi 9AH packs go on sale I plan on buying a few of them.

No load tire RPM is 264 which should be ~10mph on the 53v.


I am now on the hunt for a Razor Dune Buggy for myself which would get something like the 48v Boma systle motor. I'm all for brushless, most of my RC have brushless motors.

 

[Bmr4Karts]

Went ahead and set it up for 15s off three 18v Ryobi packs in series. Runs great and nothing is hot. Crazy that this tiny little 36v controller can take ~63v.

 

[Bmr4Karts]

So I've pretty much gone around the world with getting/making myself an electric gokart. I found a Mango Dingo 285 for $50 so that was a deal. But after moving it in and out of the basement door so I can weld on it I realized that it is way bigger than I want to deal with and that's without the wheels and axle even being on. Too bad I've already invested $1000 in a stupid powerful motor and speed controller which I'll probably hang on to in case we ever move and I buy a sprint kart chassis. So I never stopped looking for a Razor Dune Buggy and finally got one today for $75. Batts were dead so I swapped a 7s lithium ion pack I had made and it can hit top speed with my 200lbs but it has no balls. I've also already ordered two 48v brushless motor controller combos so one of those will go in the Razor. I had bought those to put on the Dingo since I'm really only trying to hit 25mph and the combo I already bought is cable of 3 times that. Functional Artist's videos showed that one of those 48v setups would be good for ~18mph on heavy kart like a Dingo so I figured a pair of them would be good for 25mph with decent acceleration and incline climbing capability.

I've already been researching the power wheels racing series and those guys are limited to 40 amps at 48v and they are hitting 18-20mph on their custom Dune Buggy sized chassis'. I figure I'll try to the Dune Buggy with one 48v bldc motor and if that's not enough I'll stick the 2nd one in there, lol.

https://www.youtube.com/watch?v=Ofw9lTtnv88

 

[Bmr4Karts]

I swear welding is such a rewarding activity. I added some 1/8" flat stock to extend the motor mount since the 1800w brushless motor has wider mounting base. I lose the slots for adjustability but I can just use washers.

 

[Bmr4Karts]

OMG. My Razor Dune Buggy is fantastic with the 48v brushless setup. It gets me up the 6ft hill next that is next to my house with no problems and hits 16mph with the current gearing.

I'm not done with placement or the battery setup, but I had to try it. Drove around hard for 5 mins and the motor and ESC were barely warm. It turns so well and I can carry it all with one hand. I will be buying another one which will get a 1" rear Axle, no jackshaft, 5/8" spindle Bolts and larger tires.

I'm 6ft 200lbs and it's very comfy. I'm sure I look dumb with my knees pointing to the sky but it's a blast so who cares.

 

[landuse]

OMG. My Razor Dune Buggy is fantastic with the 48v brushless setup. It gets me up the 6ft hill next that is next to my house with no problems and hits 16mph with the current gearing.

I'm not done with placement or the battery setup, but I had to try it. Drove around hard for 5 mins and the motor and ESC were barely warm. It turns so well and I can carry it all with one hand. I will be buying another one which will get a 1" rear Axle, no jackshaft, 5/8" spindle Bolts and larger tires.

I'm 6ft 200lbs and it's very comfy. I'm sure I look dumb with my knees pointing to the sky but it's a blast so who cares.

Nice!!! It is awesome when you get to make something that works so well

 

[Bmr4Karts]

So the stock motor on the Lighting bug finally let the smoke out. I was sure the esc would go first. I went looking for options on ebay and a 48v geared motor cost around $85. Then I remembered I still have an extra 48v brushless combo so I'm slapping it in there. I welded an 80t #25 sprocket to the stock oddball sprocket and the motor has a 11t #25. I went with 11 because that's the smallest on ebay shipped from the US. I'll probably order a 9t from China long term. I'm also drilling holes in the motor's base to match the frame. Bench test went well, scary actually. With no tires the axle is spinning at 776rpm which equates to over 25mph with the 13" tires mounted. I'll tame it with a combination of the speed switch and limiting throttle travel with the limiting bolt behind the go pedal. My 200lbs has been breaking #25H chain with my cart, but I doubt her 35lbs will cause a problem on her cart.

 

[Bmr4Karts]

Got it hooked up enough to test out and it moves me around far better than before. Gets me up the hill next to the house just fine. Top speed for me is still slow, but for her I'll need to turn it down. Now I'm finalizing the wiring and all the switches for on/off, 3 speed, and reverse.

 

[Bmr4Karts]

Switch box is all done.

On off
Voltage monitor
3 speed (no load wheel speeds are 13mph, 18mph, 26mph)
Forward Reverse