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Industrial Motor gokart build

Posted: Nov 27, 2017 2:31 am
by Quinc
Been tinkering with mini motos, mini bikes and razor dune buggies for the last couple years and wanted to get something a little more comfortable. I bought a Leeson motor off ebay for a great deal and after a year of searching I finally picked up a kart racing chassis for a decent price.

Plan:
48 volts
7200 rpms
10T drive sprocket
67T axle sprocket
#35 chain
11.5" tires

Goal:
Have fun and ride around neighborhood with kiddos

Motor:
Leeson
1HP
24vdc
3600 RPM
TEFC

Controller:
Kelly KDZ48400 24v-48v 400a controller

Batteries:
48v
Starting with SLA 12v 18AH. (I have a bunch of them from other projects, but might move on to lipo, leaf, or just larger sla's)

Kart:
Haase stage 2 (First time with a real gokart and learning as I go)

Re: Industrial Motor gokart build

Posted: Nov 27, 2017 2:43 am
by Quinc
So far the kart is a little rough.. I took off the axle and cleaned it up added a sprocket hub and am now waiting on a new sprocket. And still need to figure out how to mount the seat. Once I have it how I like it, I will strip her back down and paint etc.

Tonight I started on building a bracket for the motor to attach behind the axle. My plan as of now is to put the batteries where the engine would normally go on the kart, and moving them however needed for balance and weight distribution. I am also trying to keep from welding or drilling the frame.
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Re: Industrial Motor gokart build

Posted: Dec 06, 2017 2:16 pm
by Quinc
Kiddos' 4th bday was Saturday and also taking care of a 3m old so the build is starting off a little slow.

Ordered new rear axle bearings for her today and just got the cheapo 3pin Chinese foot throttle for it in the mail. Rather then "make" the foot throttle work I am going to go with a pull throttle.

Always a good sign when it comes new with rust.
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Not sure where the motor POS wire should go yet.
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Kelly i bought off ebay mostly wired up:
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Re: Industrial Motor gokart build

Posted: Dec 06, 2017 2:26 pm
by Quinc
Spent some time cleaning up the axle. She spins a hell of a lot smoother now with new bearings. Also a new sprocket hub and 67T #35 sprocket.
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Getting closer!
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Re: Industrial Motor gokart build

Posted: Dec 07, 2017 10:28 am
by Quinc
Motor mount is complete! Has the ability to go side to side and back-forth fairly easy. Used a 3/8" plate of aluminum.

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And started on the battery tray:
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Re: Industrial Motor gokart build

Posted: Dec 07, 2017 1:43 pm
by Drunkskunk
Looks like fun. I've had cars with less stout brake rotors.
Had a good laugh at the "Kelly" controller diagram.

Re: Industrial Motor gokart build

Posted: Jan 09, 2018 11:02 pm
by Quinc
Been slowly making progress. Have the seat mounted and spent way to much time fabing the hall effect sensor for the foot throttle. Next on the agenda is battery placement.

Re: Industrial Motor gokart build

Posted: Jan 22, 2018 11:46 pm
by Quinc
Test run this weekend! Did a quick hookup of the yi-yun 190amp controller and 4x18ah SLA batteries for 24v 36ah. Made it around the block 4 times and the engine was still ice cold. If I tried to go full throttle from a stop it would cut out. Going to try another 2x18ah batteries for 24v @ 54ah.

Doing some research and looks like I need 56ah SLA for 400amps, or I can run 16ah AGM battery for the same 400amps. Pretty interesting. So I might try 4x 35ah AGM batteries. Or if anyone has some electric car cells they want to make me a deal on. :)

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Re: Industrial Motor gokart build

Posted: Jan 23, 2018 6:41 pm
by Hillhater
I assume you realise that the Haase chassis you are using is designed and set up for oval dirt track use.
I do not expect you intend to "race" the completed kart at all, but if you do i suggest you stick to LH oval tracks as you will find that fast RH corners will be a very tricky manouver. !
You could make some adjustments to the front end geometry and wheel hub location to minimise the corner bias, but you wont be able to achieve an even corner balance.
But have fun anyway...(dirt ovals can be a LOT of fun ! :wink:

Re: Industrial Motor gokart build

Posted: Jan 23, 2018 10:43 pm
by Quinc
Hillhater wrote:
Jan 23, 2018 6:41 pm
I assume you realise that the Haase chassis you are using is designed and set up for oval dirt track use.
I do not expect you intend to "race" the completed kart at all, but if you do i suggest you stick to LH oval tracks as you will find that fast RH corners will be a very tricky manouver. !
You could make some adjustments to the front end geometry and wheel hub location to minimise the corner bias, but you wont be able to achieve an even corner balance.
But have fun anyway...(dirt ovals can be a LOT of fun ! :wink:
This is just going to be used for chasing my kids around the neighborhood on there gokarts.(neighbors less likely to call police when you are quiet) If I was going to race I would be running a 2stroke. ;)

Re: Industrial Motor gokart build

Posted: Feb 09, 2018 2:07 am
by Quinc
Hillhater wrote:
Jan 23, 2018 6:41 pm
I assume you realise that the Haase chassis you are using is designed and set up for oval dirt track use.
I do not expect you intend to "race" the completed kart at all, but if you do i suggest you stick to LH oval tracks as you will find that fast RH corners will be a very tricky manouver. !
You could make some adjustments to the front end geometry and wheel hub location to minimise the corner bias, but you wont be able to achieve an even corner balance.
But have fun anyway...(dirt ovals can be a LOT of fun ! :wink:
Well, got tired of only make left hand turns so I adjusted the front and rear wheels to line up more like a straight kart and I can now make RH turns fairly quick. :) Plan is to pick up some electric car batteries this weekend and to try her out at 44v+. Going to also pull the motor off and replace the 8ga wires with 0ga.

Re: Industrial Motor gokart build

Posted: Mar 18, 2018 7:47 pm
by garolittle
Great project. Any updates?

Re: Industrial Motor gokart build

Posted: Mar 19, 2018 5:44 pm
by Quinc
garolittle wrote:
Mar 18, 2018 7:47 pm
Great project. Any updates?
Finally bit the bullet and bought 10x 4s 5ah 25-35c battery packs. (If anyone needs something from hk use HOBBYKING10 for 10% off)

Plan is to start out at 8s 25ah *4920 rpms and depending on results I will then try 12s 15ah 7380rpms and if things are not getting too hot I will go to 16s 10ah (9840rpms)

Before I do that though I need to solder 0awg wires to my motor (currently 8ga) and figure out what I am going to use for connectors on the batteries. Plan is to use 8ga between them and 0awg to the controller and motor.

Re: Industrial Motor gokart build

Posted: Mar 20, 2018 8:14 pm
by garolittle
How much did you pay for the racing go-kart frame? That looks great. I am searching for something similar myself. Any suggestions for a newbie?

Re: Industrial Motor gokart build

Posted: Mar 21, 2018 4:29 pm
by Quinc
garolittle wrote:
Mar 20, 2018 8:14 pm
How much did you pay for the racing go-kart frame? That looks great. I am searching for something similar myself. Any suggestions for a newbie?
I paid 300$ for the kart with an extra set of new tires.
70$ for a new seat
15$ for a new sprocket
30$ for new bearings


For the best deals join any local karting facebook pages. Also try and get a race kart and not a oval kart.

Re: Industrial Motor gokart build

Posted: Mar 21, 2018 8:45 pm
by garolittle
Thanks for the response. That is helpful information. Keep us posted on your project. :)

Re: Industrial Motor gokart build

Posted: Mar 23, 2018 12:52 pm
by Quinc
Just waiting on my orders from hobbyking... Ordered another 2 lipo's so I can run 12s x 20ah.

This is currently my next plan of action if anyone has any suggestions or criticisms. :idea:

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Re: Industrial Motor gokart build

Posted: Mar 23, 2018 1:20 pm
by parabellum
Nice gokart Quinc!

Why such an overkill on controller?

Re: Industrial Motor gokart build

Posted: Mar 23, 2018 3:56 pm
by Quinc
parabellum wrote:
Mar 23, 2018 1:20 pm
Nice gokart Quinc!

Why such an overkill on controller?

Thanks! Not sure what you mean on the controller?

Re: Industrial Motor gokart build

Posted: Mar 23, 2018 4:23 pm
by parabellum
This controller can peak out at almost 20KW.
I suppose, your motor will deal at ~3KW, right?

Re: Industrial Motor gokart build

Posted: Mar 23, 2018 5:09 pm
by Quinc
parabellum wrote:
Mar 23, 2018 4:23 pm
This controller can peak out at almost 20KW.
I suppose, your motor will deal at ~3KW, right?
Beauty of industrial motors is they will take whatever you can throw at them and smile. As they are built to run 24/7/365. However, they are not as efficient. :|

Re: Industrial Motor gokart build

Posted: Mar 23, 2018 5:50 pm
by Quinc
Reading the motor nameplate:

RPM: 3600
HP: 1
SF: 1.00 = Motor can increase torque by 10% to handle increased loads
MAX. AMB: 40°C = Do not run the motor when the outside temp is above 40°C
VOLTS: 24vdc
AMPS: 41
DUTY: CONT = motor can run 24/7/365
FRAME: VS56C = See picture of motor mount
TORQUE: 17.5 in lbs = 1.45 foot pounds
ENCL: TEFC = Totally Enclosed, Fan-Cooled
TYPE: DF = Direct current Fan cooled
F.F: not sure
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Re: Industrial Motor gokart build

Posted: Mar 23, 2018 6:38 pm
by parabellum
Yes, that why. I suppose it is 24V/41A=0.585Ohm motor, in dynamic state. At 43.2V/0.585Ohm=73.8A. And finally, 43.2Vx73.8A=3188W.
You certainly can throw all you wish at it, but need to raise the voltage correspondingly.

Re: Industrial Motor gokart build

Posted: Mar 28, 2018 5:54 pm
by Quinc
Chose the 2-7 day shipping option and now 10 days later my order is still processing. =/ Have most of the connectors coming from ebay. Just need to get 12x XT90 male connectors and I will be ready to rock once the batteries get here..

Re: Industrial Motor gokart build

Posted: Mar 28, 2018 5:59 pm
by Quinc
parabellum wrote:
Mar 23, 2018 6:38 pm
Yes, that why. I suppose it is 24V/41A=0.585Ohm motor, in dynamic state. At 43.2V/0.585Ohm=73.8A. And finally, 43.2Vx73.8A=3188W.
You certainly can throw all you wish at it, but need to raise the voltage correspondingly.
I am not a rocket surgeon, but the way I understand it; the motor will pull as many amps as it needs/can to get up to speed. So running at 3600rpms and only needing 1hp it will pull 41A. However, if pulling my 220lb arse up a hill from a dead stop the motor will pull as many amps as it needs/can. And if it needs 200amps to do it it will pull the 200amps until either the motor fails or overheats etc.