Electric go kart parts checklist

Hi!

I'm working on my first electric go kart project and would like to purchase all the needed parts. Before I do that, however, I'd like to ask you for advice: please let me know whether you think the combination of parts below makes sense (isn't a waste of money and will work well together) and whether I have forgotten anything essential or particularly useful. Thanks!

I'm basing my design on a wiring diagram by Kelly

Motor: 0909 Mars Brush-type PMDC motor (http://www.motenergy.com/me0909.html)
I'm planning to build the motor bracket myself. Shouldn't be too difficult, I hope...
Controller: Kelly KDZ48300 (https://kellycontroller.com/shop/kdz/) + J1 and J2 cables for connecting throttle, lights, etc. to the controller (https://kellycontroller.com/shop/j2-cable/) + RS-232 to USB for programming + 14-pin connector (is it necessary???) (https://kellycontroller.com/shop/14-pin-connector/)
0-5V throttle (https://kellycontroller.com/shop/simplified-0-5v-throttle-pedal/)
10A car fuse https://images-na.ssl-images-amazon.com/images/I/21t5hCHvhfL.jpg
300A fuse (https://kellycontroller.com/shop/ane-fuse/)
48V 400A contactor (https://kellycontroller.com/shop/kzj-400a/)
200V 3A diode (https://www.conrad.at/de/p/diotec-si-gleichrichterdiode-1n5402-do-201-200-v-3-a-162388.html)
1kOhm 25W precharge resistor (https://www.conrad.at/de/p/widap-160042-draht-widerstand-1-0-k-im-gehaeuse-25-w-1-1-st-1525156.html)
11 teeth, 428 type chain sprocket for the motor (not sure if this one will fit and whether it's the right choice in general. Any advice?) (https://www.amazon.de/Motorritzel-f...eywords=ritzel+go+kart&qid=1579186278&sr=8-66)
Key for the motor sprocket (https://www.amazon.de/Schlüssel-qua...words=keilnut+schlüssel&qid=1579189969&sr=8-4)
428 chain, 116 links (https://www.amazon.de/Kette-Glieder...ÅŽÕÑ&keywords=428+kette&qid=1579191093&sr=8-5)
A used, standard go kart chassis - standard wheels, steering, brake, etc. (something like https://www.willhaben.at/iad/kaufen-und-verkaufen/d/go-kart-355671244/)
A 428 drive axle sprocket, in case the chassis has a non-428 sprocket installed (https://www.amazon.de/Vobor-Kettenr...ÅŽÕÑ&keywords=428+kette&qid=1579187645&sr=8-7)

As for batteries, I have a Stiga 48V 5Ah Li-Ion pack lying around and I was thinking of using it for testing the system and maybe riding for a short time. I'm planning to simply use the + and - terminals that are available (https://images-na.ssl-images-amazon.com/images/I/81tLgs1b1dL._AC_SL1500_.jpg). (not sure what the Ohm and C ports are for...) Is this a good idea to get started?
Anyways, later I would buy proper batteries. My budget for them is around 300 Euros ($334). One idea I have is to put four of these in series: https://www.amazon.de/8000mAh-Lipo-...MKHSJPRAT58&psc=1&refRID=62KJA44QQMKHSJPRAT58
I realize that it's not a lot of juice, but I'd like to actually use the power the motor can provide even if it means riding only for 5-10 minutes, instead of having more ride time, but going slower - if I'd buy lead acid batteries, for example. Are there any other good options for that price?

And, finally, I would get a charger for the batteries.

So, what do you think? Have I forgotten anything? I'd appreciate your help a lot!

Karts can have various axle sizes. 25,30, 40,or 50mm depending on its history.
You will need a suitable sprocket adaptor to fir your sprocket to the axle.
Note:- most karts us “219” special chain and sprockets...it may be easier to find components in that range from kart shops.
Battery selection will be your biggest issue..capacity, size , weight , location on the chassis, etc.
There are several Ekart builds on this forum that you may learn from

Thanks for the advice!

I'd like to switch to a 219 chain, but after searching for many hours I gave up on finding a motor sprocket that would fit the ME0909. 219 sprockets that would fit the 7/8" (22mm) shaft don't seem to exist. 428 fitting 7/8"? No problem. 219 fitting 3/4"? Sure. 219 on a 7/8"? No luck. Please, if you know of a sprocket that would fit, let me know. Otherwise, I see no other good option than going with the 428 I posted above.

I'm doing it very differently. https://endless-sphere.com/forums/viewtopic.php?f=30&t=100331&p=1522732&sid=c5b4e38a81c4c7cba107feb6c744cb90#p1522732

428/219..
Choice is yours, which ever is easier,.( Karts use 219 because it gives a wider range of single reduction ratios)
There will be suppliers (Comet, Asuza, Phifer etc) that with either have suitable parts in stock or can make parts to order.
.just be sure you know what axle size you are working with, before you order sprockets and carriers

PKGB said:

I'm doing it very differently. https://endless-sphere.com/forums/viewtopic.php?f=30&t=100331&p=1522732&sid=c5b4e38a81c4c7cba107feb6c744cb90#p1522732

Click to expand...

Do you have any videos of the kart's performance?

Hillhater said:

428/219..
Choice is yours, which ever is easier,.( Karts use 219 because it gives a wider range of single reduction ratios)
There will be suppliers (Comet, Asuza, Phifer etc) that with either have suitable parts in stock or can make parts to order.
.just be sure you know what axle size you are working with, before you order sprockets and carriers

Click to expand...

Thanks for the suggestion. I couldn't find a 219 sprocket for 7/8", unfortunately. I'll consider having them made to order, if that's the only option I have left.

Maybe I should also mention that my budget is around 1000€ ($1100). Run time can be as little as 5 minutes; what I care more about is the performance during that period. But it would be nice to be able to ride longer as well, of course. Very good acceleration is my priority. Keeping that in mind, about 50 KPH (30 MPH) max speed would be more than enough.

Anyways, it looks like I'll have to change my plans a little... I wanted to buy the Motenergy and Kelly because I was hoping that I could get them for about $570. Unfortunately, that offer has since risen to $720. I don't think that's worth it, considering that I'll have only about $400 left for the chassis, batteries and all the little parts and accessories.

So, instead, I'm now thinking of buying a Golden Motor 3 kW motor (https://www.goldenmotor.com/frame-bldcmotor.htm), along with a Kelly mini controller (https://www.kellycontroller.com/shop/kbs-e/). Both the 48 V and 72 V versions of the motor have the same price, and according to its datasheet, I should be able to get more performance out of the 72 V version (48 V: https://www.goldenmotor.com/hubmotor...KW%20Curve.pdf For 72 V see attachment). On the other hand, I worry that I'll have to put more batteries in series to achieve that voltage, which will increase the cost. Then again, the amperage will be lower, so I'll save some money on smaller gauge wires. Do you guys think that it's worth it to go for 72 V? Or should I stay in the 48 V range, considering my budget and goals?

If I'd go with the 72 V motor, I would pick the 72 V, 80 A controller version. BTW, do you know what the "High Speed Motor" option on controller's website is for? Is it of any use in my case?

And as a quick side question: looking at the motor diagram (https://www.goldenmotor.com/hubmotor...%20Drawing.pdf), do I understand correctly that the shaft has a diameter of 3/4"? That should make it a lot easier to find 219 sprockets for it, compared to Motenergy's 7/8" shaft.

I appreciate your advice a lot, guys. I know this is a lot of info and questions I'm throwing at you... I've been researching these parts for weeks now, and I'd like to be able to finally place an order. Unfortunately, I have limited time to finish this project, so I need to get going soon. Thanks!

That looks pretty good! But in the end I've decided to order the 3 kW, 72 V Golden Motor and the 72 V, 80 A Kelly controller. Now I only need to pick the batteries + accessories and find a frame to put it all onto. But I think that's more appropriate for a new thread, so I'll go ahead and start one.