• Build Log #2 - We Have Motor!

    Andy Shinn6 days ago 0 comments

    The motor is mounted! Big thanks to Matt for helping us out in his shop. We were able to cut out our aluminum panel for the controller mounting and weld up the motor brackets.

    The mount is a piece of 2" x 1" rectangle tubing between the seat cross tube and end of the brake caliper bracket. There are two pieces of 1-1/2" angle perpendicular to the tube which we drilled holes to mount the motor plate. Everything feels very sturdy.

    We also got the rear panel cut and mounted. Instead of the pipe clamps Matt suggested we use some self-tapping steel screws into the frame. This should work out nicely and I'll later add some rubber washers and trim to the panel to cut down on vibration.

    Less interesting but still relevant is a small adapter I made that connects up the motor signal wires (sine, cosine, temp) to the controller. This is a Metri-Pack 150 8-way male pin to DJ7061Y-2.3-21.

    The frame mount changes have been added to the CAD drawings and I rearranged some parts for better fit. I'm now thinking that the contactor and BMS will go on the side of the battery box and the throttle POT will go where I originally had the BMS.

    I've finalized most of the control panel and ordered parts to start wiring it. But hard to get length of harness without the battery box in place. Still waiting on the batteries!

    That's all for now. Stay tuned for battery build and more electrical updates soon!

  • Build Log #1 - Parts Ordered!

    Andy Shinn04/21/2021 at 16:24 0 comments

    The project now has legs.... or rather, wheels!

    We have ordered parts and I made the 7 hour trip to Keller, TX to pick up the vintage kart kit.

    In addition to the frame we have the other major parts ordered as I finally settled on a setup I hope will work well:

    • Motenergy ME1718 motor.
    • Kelly KLS72501-8080IPS controller.
    • Headway 38120HP cells x 40 for the 20S2P battery pack.
    • Chargery BMS24T-300 and charger combo for battery management.
    • Chargery DCC-300HB for main contactor.
    • Curtis PB-8 Throttle Pot for throttle.

    There are still a lot of parts left on the list (wiring, terminals, mounting plates, 3D printed parts, fasteners, etc). But these are the major cost components and they are en route!

    In addition to gathering parts I've been spending a ton of time in OnShape trying to model up how everything will fit together. There are a couple custom parts to be made:

    • Motor mount. A plate has been ordered and the current plan is to have it welded directly to the tube frame over the left rear.
    • Battery box. I'm thinking this will be acrylic since it is rather large to be 3D printed. But TBD.
    • Brackets for holding BMS and contactor in place. These can be 3D printed and should be straightforward.
    • Large plate on back of seat for mounting controller, BMS, and wiring. I was thinking sheet metal aluminum or steel. But maybe acrylic could work? TBD.
    • Switch controls under wheel. For parking brake, reverse, eco mode, and power switches. Should be 3D printable. Held to posts with hose clamps or other fastener.
    • BMS SOC display mount behind wheel. 3D printed like controls. Holds the display module.

    That is it for this update. Parts start arriving next week so stay tuned!