Wiktor Wise
Building an electric cart at home is a fun and challenging project. While it may be time-consuming and require some technical know-how, it is possible to create an electric go-kart with basic tools and mail-order parts. The process involves sourcing a suitable motor, battery, frame, and other components, as well as making design decisions to ensure comfort, performance, and safety. With careful planning and execution, you can build an electric cart that is quieter, lighter, and more environmentally friendly than its gas-powered counterparts.
| Characteristics | Values |
|---|---|
| Motor | GE 36V motor, Washing machine motor, 6.5-horsepower engine, 1HP 800w brushed motors |
| Speed controller | Curtis controller, Torque-ESC-VESC-BLDC electronic speed controller, KUNRAY-BLDC-72V-3000W-Brushless-Motor-Kit |
| Hand throttle | Converted to foot throttle |
| Charge port | N/A |
| Battery charger | N/A |
| Batteries | 48V 20AH 4c, 3 x 12V sealed lead acid batteries, 4 x 12 volt batteries, Hawker, Cyclon, Gel cells |
| Wheels | Old wheels, Radio Flyer wheels |
| Steering | Tiller steering arm, Steering adapter |
| Seat | LEIFARNE seat shell |
| Frame | Racing chassis, Square tube |
| Cost | $60, $160, $600, Under $1000 |
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$259.99
What You'll Learn
Sourcing parts
Engine and Motor
You can opt for a 6.5-horsepower engine, which can be purchased from stores like Harbor Freight for around $160. Alternatively, you can explore the option of using a washing machine motor or a GE 36V motor, which has a base mount similar to gasoline engines. If you're looking for something more powerful, golf cart motors are also an option, typically ranging from 8-11HP.
Batteries
The type of batteries you need will depend on your voltage requirements. For a 48-volt battery pack, you can connect four 12-volt batteries in series. Ensure you connect them in a series connection and avoid completing the circuit by connecting all batteries in a loop, as this can cause an explosion. SLA batteries are another option, rated for a maximum current draw of 255A.
Wheels and Suspension
You can source wheels from various places, such as old wheels from a neighbour's shed or wheels from a Radio Flyer wagon. For suspension, you can cut and weld parts from a cheap ATV purchased second-hand. Alternatively, you can use pillow blocks to keep the rear suspension solidly mounted.
Steering
The steering assembly can be crafted using old 1" square steel tubing, often found in commercial clothes racks. You can also 3D print a steering adapter, which allows the wheel to bolt up to smaller screw-mount nuts.
Controllers
Controllers are essential for regulating the speed and performance of your electric cart. You can purchase speed controllers and motor controllers from online stores like Hyperpowersports.com or Aliexpress. For a more affordable option, you may want to consider using a generic controller, which can be found on Aliexpress as well.
Chassis and Frame
The frame of your electric cart can be constructed from various materials, such as square tubing or old bed frames. If you're on a budget, keep an eye out for old go-karts or racing chassis that you can restore and modify. Ensure you clean the frame of any corrosion and remove any gasoline components before building.
Remember, when sourcing parts, it's essential to be resourceful and adaptable. Many of these components can be found second-hand or repurposed from other projects. Always prioritise safety and functionality in your design choices.
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Assembling the frame
When assembling the frame for your small electric cart, it is important to start with a solid foundation. You can either build your own frame from scratch or, if you have the right parts, you can modify an existing frame to suit your needs.
If you choose to build your own frame, you will need to have the necessary materials and tools. Steel tubing, for example, can be used to create a sturdy frame, but you will need to be able to cut and weld it to the desired specifications. Consider the size of your cart, the weight it will need to carry, and the terrain it will traverse when designing your frame.
Alternatively, you can modify an existing frame to suit your electric cart conversion. For example, you can start with an old go-kart frame, cutting and welding additional parts as needed. Ensure that the frame is free of any corrosion and that any unnecessary components, such as gasoline engine parts, are removed.
If you are working with a small or short frame, consider whether it will comfortably accommodate your legs. You may need to extend or reinforce the frame to ensure it is the right size for your needs.
When assembling the frame, pay close attention to the suspension. A solid rear suspension can be uncomfortable and may cause the cart to become unstable during use. Consider cutting and welding in a new rear suspension setup, such as leaf springs, to improve ride quality and stability.
Finally, remember to plan for the placement of your electrical components, such as the battery and motor. Distribute the weight evenly to maintain steering control and grip on the rear wheels. Secure the batteries with a sturdy setup, such as plywood strapped down with tie-downs or a welded metal container.
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Installing the motor
Firstly, you need to select an appropriate motor for your cart. Consider factors such as the desired speed, load capacity, and type of terrain you intend to use it on. For example, if you require a higher speed, you might opt for a more powerful motor, such as a 6.5-horsepower engine.
Next, you must prepare the motor for installation. This includes ensuring that the motor is compatible with your cart's frame and drive system. If you're converting from a gas-powered cart, as in the case of one user who transformed a rusty old go-kart, you will need to remove the gasoline components and clean up any corrosion on the frame.
Now, it's time to mount the motor. One user chose a GE 36V motor with a base mount similar to the mounting pattern of the gas engine, which made installation easier. You may need to weld or bolt the motor into place, depending on your cart's design. Ensure that the motor is securely attached and aligned correctly.
After mounting the motor, you'll need to connect it to the drive system. This typically involves using a chain or belt to transfer power from the motor to the axle or wheels. One builder used a motorcycle chain and welded gears together to match the motor and drive gears. Ensure that the chain or belt is properly tensioned to avoid slippage.
Finally, you'll need to wire the motor to the rest of the electrical system. This includes connecting it to the controller, battery, and any other components like a hand or foot throttle. It is important to follow wiring diagrams and instructions specific to your motor and components to ensure a safe and proper connection.
Building your own small electric cart can be a rewarding project, but it's important to approach each step carefully, especially when dealing with electrical components and power tools.
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Wiring the components
Firstly, you need to decide on the type of motor and controller you will be using. You can choose between brushed and brushless motors, each with its own advantages and disadvantages. For the controller, you can opt for a generic one or a more specialized option, such as the VESC controller. Consider the power requirements and compatibility with other components when making your selection.
Once you have your motor and controller, it's time to connect them. Ensure you follow the manufacturer's instructions for any specific guidelines. Typically, you will need to connect the motor to the controller using the provided wiring harness or by soldering the wires directly, following the correct polarity. Secure all connections with electrical tape or heat shrink tubing to prevent short circuits.
The next step is to wire the batteries. For a 48-volt system, connect four 12-volt batteries in series, ensuring you connect the positive end of one battery to the negative end of the next. Do not complete the circuit by connecting the batteries in a loop, as this can lead to an explosion. Use strong metallic wire terminals for high conductivity and firmly crimp the wires to prevent loose connections.
Now, you can connect the contactors, fuses, and other electrical components. Follow a wiring diagram if one is provided, or consult an electrician if you're unsure. Ensure that all connections are secure and insulated. You may also need to connect a key switch and a forward/reverse rocker switch, depending on your design.
Finally, test your wiring by connecting the battery and controller, and turning on the cart. If everything is wired correctly, your cart should come to life. If there are any issues, carefully check your connections and consult your wiring diagram or a professional for guidance.
Remember, always exercise caution when working with electrical components, and if you're unsure about any aspect of the wiring process, seek advice from a qualified electrician or a forum with experienced builders of electric carts.
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Testing and troubleshooting
Battery and Charging:
- Start by verifying the proper voltage for your battery type. Most electric cart batteries operate within a range of 12 to 48 volts.
- Utilize a multimeter to check the charge on each battery individually. First, remove the clamps connected to the battery cables for accurate readings.
- If a battery is completely dead, it may not recharge. Attempt to use an external charger, or consider replacing the battery.
- Batteries lose voltage even when not in use, so ensure your cart is charged before use, especially if it has been dormant for a long period.
Solenoid:
- The solenoid is a crucial component that allows electricity to flow from the batteries to the electric motor.
- Listen for a clicking noise when you turn the key to the "on" position. This indicates a functioning solenoid.
- If you don't hear the click, there might be an issue with the solenoid. Check for loose wires, broken coils, or corrosion.
- To test the solenoid, disconnect the wires from the large terminals while keeping them organized for easy reassembly.
- Set your multimeter to ohms and place one contact on each terminal.
Motor:
- If your cart still doesn't operate after charging and resetting the battery, the motor may be the issue.
- Expose the motor by using a screwdriver. Look for a small red reset button near the main power supply and press it.
- After reassembling and charging, if the cart still doesn't run, the motor may be burnt out and require replacement.
- Inspect the motor for damaged bearings, coils, or brushes. Small parts can be replaced, but larger damage may necessitate a new motor.
Potentiometer:
- Locate the potentiometer and examine it for any cracks, broken parts, or disconnected wires.
- Ensure the electrical signal on the potentiometer matches the range on the controller; otherwise, the cart won't run.
- Adjust the lever on the potentiometer, which controls the cart's speed, as it may have slipped and affected the signal transmission.
- Utilize a multimeter to test the potentiometer's output. Most golf cart potentiometers are 5K – 0 ohms.
Wall Socket:
- Test the wall socket where you charge your cart. Use a 120-volt tester to check the socket.
- If there is no voltage reading, the socket is faulty and may need replacement or a reset of the circuit breaker.
General Notes:
- Electric carts, like any electric vehicle, commonly experience issues with batteries, motors, and related components.
- Troubleshooting can save you time and money by identifying issues that you can fix yourself without professional maintenance.
- Always exercise caution when working with electrical components, and if you're unsure, seek assistance from a qualified technician.
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Frequently asked questions
You can start by deciding on the frame of your cart. You can use an old go-kart frame or build one from scratch. If you're using an old frame, make sure to clean it up and remove any corrosion or unwanted parts.
The main components you will need include a motor, speed controller, throttle, charge port, battery charger, and batteries. You can purchase these parts online or salvage them from other sources.
For a 48-volt battery pack, connect four 12-volt batteries in series by joining the positive end of one battery to the negative end of another. Be careful not to complete the circuit by connecting all batteries in a loop, as this can cause an explosion. Connect the contactors, fuses, motor, and controller as part of a larger circuit.
You can use plywood or a metal container welded to the frame to mount the batteries. Distribute the weight evenly to maintain steering control and grip on the rear wheels.
You can source parts from various places, including second-hand markets, local hardware stores, or online retailers like Aliexpress or Hyperpowersports. Consider salvaging parts from old vehicles or equipment, such as go-karts, ATVs, or golf carts. Be creative and adapt parts to fit your needs, such as welding gear parts together or converting hand throttles to foot throttles.
