Homemade 2000W Go Kart

Designed, built, and tested my completely custom 2000W Aluminum-Oak composite CyberKart. The project took roughly 3 months of work to complete spanning 1 and a half year.

Custom 48V, 40A 13S8P 104-cell Lithium-ion Battery Pack

Soldered Battery Pack

104 Lithium LG cells wired in a 13s8p configuration. Each cell can safely output 10A nominal, meaning this battery pack has a maximum continuous current output of 80A! This yields a theoretical max continuous power of 4500W from my battery pack and a peak power of 7000W!

Protected and Limited Configuration

I attached a BMS(Battery Management System) to the battery pack which limits the continuous output current to 40A. I've also designed a case made from aluminum and plexiglass which would prevent damage from accidental impacts. The power is limited as my motor can only sustain 2000W.

Lightweight Oak-Aluminum Frame Construction

Custom Suspension, Steering, and 2000W Electric Drivetrain

Everything is hand built and implemented by me.

The only stock parts I used was the rear axle, suspension control arms, and quick release. Everything else was designed, machined, and assembled by my in my living room. I'm currently designing my own rack and pinion steering system using pre-cut gears.

I chose Oak and Aluminum as they are very lightweight materials with high strength properties. The chase is designed to support up to 500kg before yielding while the rear axle has 4 bearing mounting points connecting to the base aluminum rails and oak frame.

4" Wheel Spacers, Underbody Layer, First Test-drive, Brakes, and Bodywork

4 Inch Reinforced Spacers

Each rear wheel has a 4 inch wheel spacer composed of 1/2in plywood layers reinforced with stainless steel threaded collars which mate with threaded rods attached to the hub mounts.

1/4 Inch Plywood Shell

The bottom of the CyberKart is lined with a plywood layer which protects the driver and electronics from rocks and other road debree. Additoonally, a steering wheel and electronc control panel was added.

First Test-drive

The first test included a quick drive up and down my street. This test was successful as the kart made it back in one piece. However the steering failed while driving back into the garage.

Brake Lines

Brake lines set up for both front wheels, providing equal braking power while allowing the rear to spin freely. This allows the kart to operate as a drift-kart.

Cardboard Bodywork

I created a double-layer, fiber reinforced carboard bodywork that fits perfectly overtop the CyberKart and can be disassembled in minutes. I chose cardboard as it much cheaper and easier to work with, while also reinforcing it with fiber tape.

Final Painting and Assembly

After completing the bodywork, I painted and detailed the panels to create this cartoon-like style. All the bodywork and detailing was done by hand and completely improvised. The initial shape I had modeled in my head and build the panels from a mental image. I've also added 4 12V fans to provide cooling for the motor and driver.

GoKartWorkTermReport.pdf

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