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Discussion Starter · #1 ·
Hello,

I`m Roel, an engineer from The Netherlands.
I wanted to share this project with you guys, and see what you think.
We started on this electric kart as a test and promotion project for electric driving.
The plan is to use a ME1616 motor and a Sevcon Gen4 controller running at 96V.

We got this used donor frame intended for a twin motor setup. This has a beefier frame and double frame rails on both sides to handle all that extra weight of batteries we want to put on.
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We drew up the layout in CAD to figure out the positions for the main components.
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After that out comes the cardboard and tape so we can get an idea on the space claim of all the parts.
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That should be fun. Since you have a twin-engine chassis anyway, have you considered using separate motors for the left and right wheels?
 

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Discussion Starter · #3 ·
Hey Brian,

We did not consider that actually. To keep this simple (or at least less complicated) we chose to use just one motor. This one can make around 50Hp so that should be plenty.
We ordered the motor and controller already so no way back I guess :)
 

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Discussion Starter · #4 ·
The design of the battery packs is now finished and we ordered the sheet metal housings and brackets for it.
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Discussion Starter · #5 ·
The Me1616 motor and Sevcon controller arrived. We started to wire it up to see if we could get it going.

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Awesome project 👍 I'm guessing wheelspin will need to be checked with full torque from zero. Please keep us posted - including full specs and decisions behind them .
 

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Cool! Love that frame! Looks like a pretty serious project. Would love more details about the design decisions, etc. What are you using for battery? That's the next question mark to tackle on my budget electric kart build.
 

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Discussion Starter · #8 ·
The sheet metal parts arrived. Housing for the electrical components, battery boxes and a controller box. These are test fitted onto the frame.
Also the steel brackets are welded in place. The frame is send out for powdercoating.
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Those boxes look very nicely made; hopefully they're aluminum to keep the weight down.

I suggest keeping an eye on the welds where the battery box brackets attach to the frame - the frame is intended to flex, and the way the brackets are rigidly welded across multiple points may twist the brackets and crack welds. If you ever need to re-do these brackets, I suggest bolting them to the frame at three points each - the seat mounts would be good for one each, and the nerf bar mounting stub for another. The others could be clamped around frame tubes; a tube could run laterally from bracket to bracket over top of the frame to cantilever the brackets out.
 
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