Polaris

[Functional Artist]

I didn't do a video while building the 14S 48V 15AH battery pack for Polaris
...but, I took some pics

First cell stuck thru the holder, with the tabs bent over

I used basically the same procedures, as when I built a similar 14S 48V 15AH battery, pack last year

* I added individual "leads" to each of the cell connections, to be able to connect a cell monitor

 

[Functional Artist]

To make up a battery box I did some markin' on a piece of steel

Then, did some cuttin'

Then, did some bendin'

Front side

Back side

 

[Denny]

Yay, origami!

 

[Functional Artist]

Yay, origami!

Real Men do metal oragami

Metal Rules

 

[Functional Artist]

I'm going to mount the shunt (a measuring device that mounts inline with the Negative battery cable & sends info to the PZEM-051 power meter, up on the dash)

Right in front of the battery, inside of the battery box (should be a good-n-safe spot)

To keep it insulated ...from ...well...everything (battery connections, terminals, steel box etc.)
...the shunt will reside inside of a piece of vinyl tube
Like this

...& have a couple of modified rubber grommets, on each end to help seal 'em' up & look a bit more professional

Kinda like this

 

[Denny]

I'm going to mount the shunt (a measuring device that mounts inline with the Negative battery cable & sends info to the PZEM-051 power meter, up on the dash)
View attachment 143195

Right in front of the battery, inside of the battery box (should be a good-n-safe spot)
View attachment 143194
To keep it insulated ...from ...well...everything (battery connections, terminals, steel box etc.)
...the shunt will reside inside of a piece of vinyl tube
Like this
View attachment 143196
...& have a couple of modified rubber grommets, on each end to help seal 'em' up & look a bit more professional
View attachment 143197
Kinda like this
View attachment 143198

Plus it helps keep the fire more centralized and located in one spot.


Hell’o Kevin you know I like you buddy! I only kid you because I like and respect you!
Denny

 

[Functional Artist]

Plus it helps keep the fire more centralized and located in one spot.


Hell’o Kevin you know I like you buddy! I only kid you because I like and respect you!
Denny

Hey Denny,
No worries, pal

Next, I made up a "tray" or bottom for the battery box

Battery box assembled

* Notice there are (3) separate groups of wires coming out of the battery box
1. The connections for the shunt (upper)
2. Charge/discharge connector/battery cables (middle)
3. BMS (Battery Monitoring System) wiring harness (lower)

* Tip: An old sanding sponge easily rounds & smooths the sharp edges of sheet metal

 

[ezcome-ezgo]

You'll be leaving green streaks on the driveway in no time.

 

[Functional Artist]

Battery box cover
Rough idea/notes

Piece of plastic (easily scribed & cut with this "little guy")

Used the cut off wheel for these little/short cuts

* Notice the bend lines? (marked on the inside of the piece)

Set up a heating station
...& placed the piece of plastic on 2 boards spaced ~1" apart

...then, placed 2 boards on top of the plastic (also, spaced ~1" apart)

** The bottom boards are to "space" the piece of plastic, above the workbench
...so, the heat can easily "pass thru" (the piece)

The upper boards helps to protect the areas of plastic that we don't want heated
...& also, helps concentrate the heat, in just in the area, that we want heated

Ugggg, I bent it backwards

Re-heat
...& re-bend
Ok that's better
Added a couple more bends

After a little bit of trimmin'

 

[Functional Artist]

Industrial Velcro

Clean/de-grease, the (2) areas

* Installation tip:
First, join the (2) pieces of Velcro together
...then, peal back the protective cover
...& stick/mount the (2) joined pieces, where they should be

Then, peal the other protective cover off
...& simply align & mount the adjoining piece, where it should be

 

[Functional Artist]

The (4) 12V 20AH SLA's have been removed

When removing the Belly Pan, I noticed that it & the bolts have "taken a couple of hits"

I took this opportunity to weigh the chassis
Just stood it up on a bathroom scale

Looks like the entire kart (without batteries) weighs just a bit over 100 lbs.

 

[Functional Artist]

14S 48V Lithium battery pack installed

...& then, dry fit some CAD "nose" body work

Another view

 

[Functional Artist]

I got my helmet, for safety

...& ready for a test run, with a 14S Lithium battery module

 

[Master Hack]

Looks like yer gonna beat your previous estimated GVWR by a bunch!

 

[Functional Artist]

The ghost of Polaris

Happy Halloween ya'all

 

[Denny]

Happy Halloween!

 

[Functional Artist]

Looks like yer gonna beat your previous estimated GVWR by a bunch!

Hey T,
I'ma thinkin' the whole package should Gross Out, just over 300 lbs. (He...he...I said Gross Out)

Chassis ~100 lbs.
Batt pack ~ 30 lbs.
Driver ~150 lbs.
Ballast ~30 lbs.

* I didn't "do the math" before hand
...& was kinda surprised, when the top speed jumped all of the way up to 29 MPH

 

[Master Hack]

Still, under yer original estimate! Once the bearings run in some you might pick up a bit more.

 

[Denny]

Yea Kevin, don’t you know you have to break in those little balls of yours!

 

[Functional Artist]

Did anyone notice the front wheel goin' all wonky (ex: ~10:55) a couple of times, in the last video?

Upon further examination, it seems/looks like the steering shaft is flexing (up to ~1/2") in the middle

So, I may have to add a center support
...but, for now, I just stiffened 'er up
...& we'll see how that goes

I've been workin' on a center support for the steering shaft

Side view

Profile

Mounting bracket

Dry fit

Profile

Up close

* Adding a bearing or bushing in the middle of a shaft, isn't the easiest thing to do
...because, "if" the bearing isn't pretty well centered, on the shaft (in between the other (2) bearings) there will be binding

Especially if welding the bearing holder "in place"
...because when welding, it "draws" the (2) pieces of metal together a little bit
...& again, "if" the bearing isn't pretty well centered, on the shaft there will be binding

So, my plan is to weld the bearing support bar, on to the chassis
...& then, bolt the bushing holder, to the support bar