These remarkable torquey motors are made from repurposed generator cores, wound to handle up to 10kw continous each. The planetary gearbox increases torque to a theoretical 200Nm and fits neatly inside both rear wheel hubs. Testing so far has shown speeds as predicted although torque testing remains to be seen if these motors are up to spec. They use PMSM controllers and are roughly 16 inches long and weigh in at 40lbs each.
This part is definitely the most ambitious part of this entire build and relies on many skills learned from Cal Poly Pomona's Formula SAE Electric team. Serving on the battery team and working my up to powertrain lead, I learned the required skills to build a battery pack safely and design these high power systems from the ground up. This pack uses 96x 15Ah Lithium Iron phosphate cells in a 24s4p configuration to get a 76.8v system capable of delivering bursts over 300A.
Formula SAE module for comparison, an entirely different layout but same energy capacity with a 3D printed structure
After several iterations and countless tube changes, the chassis design was finalized having excellent rigidity. With the tubes ordered and cut, there is much welding to be done before it is completed. Weighing around 80lbs wih a 600lb combined occupant capacity including a safety margin, this chassis ties all the systems together and will serve as the ridgid core of this go-kart.