So, my business has been selling quite a few of the Motenergy and Sevcon packages, and I've come to need my own vehicle as a test bench. A motorcycle is too limiting for easy change of a motor, so I started looking at Karts. I wanted an offroad kart, but they take up a lot of room and I'd need a trailer. Then I found a nice Race Kart near me that was super cheap and didn't have an engine...... and I bought it. It was in great shape and he threw in a Kart stand, Engine mount and a race computer.
So I'm documenting the build here (and my personal project site http://excessive.engineering/
Swiss Hutless Race Kart (Hydraulic disk brakes, adult size)
Motor: I'll start with an ME1507
, then an ME1304
and finally try an Zero 75-7 High Temp I'm getting
Controller: Sevcon Gen4 Size 6 for now, but I've got a Size 4 coming that I'd like to also test
Battery: I found some Saft VL41M
batteries for sale and I couldn't turn it down. Working on getting these delivered now. I'm thinking I'll try to pack as many as I can and do at least 2p. The cells have a 150A continuous and 300A for 30s rating, so that would be 300A continuous and 600A for 30s if I did 2p. I'd like to get as close to 72V as I can, but ultimately it depends on how many fit on the chassis. They're large cylindrical, 41Ah LiIon batteries. About 8.75" tall and 2.2" in diameter with screw terminals for connection to buss bar. They weigh about 2.35lbs each.
BMS: Thinking about ZEVA V3 BMS, one for each side.
Motor Mount: I'm getting 2 of them to test. The other will be used as a bench motor-mount.
1) Original Kart Engine mount + Manta 2 Motenergy Base Plate from eBay
2) Kartmasters.fr kart mounting plate.
Made to bolt onto the kart and motor without modification
Motor: Amp 428 pitch 11T 7/8" sprocket
Axle: 28T 40mm hub 428 pitch aluminum
to replace the 40mm hub and 219 pitch sprocket that is on there now
Display: Sevcon Clearview
for now, but working on something else.
Charger: Offboard DeltaQ QuiQ programmed for Lithium.
Wiring harness: EMF-Power Sevcon Harness
DC-DC: Sevcon 500W
for powering BMS and any other LV things I need. I may eliminate this and use a small 12V pack.
I'm trying to use as much of the items I currently offer at www.emf-power.com
, so they get some extra testing, and people can see how reliable they are in practice. Plus, I can make tweaks and test for people much more easily.
Here's a ME1507 setting on the frame for reference:
Here's a ME1304 setting on the Engine mount for reference: