Hacky racers build

Requirements

These are the things we have to get done as a minimum.

• Under £500
• Bumpers
• Foot Protection
• Brakes
• Battery Retention
• Kill Switch
• Fuse 48v = 30A Fuse (Digikey #F7139-ND) BF1 series
• Transponder
• Size limits, 1500mm (62) length, 900mm (36) width

Parts

Go kart frame

Around 17kg estimated

Wheels 25 cm diameter

Motor

Specs

• Brand Name: BOMA
• Product Name: Brushless DC Motor
• Voltage: 48V
• Power:1600W
• Rated Speed: 4800rpm
• Rated Torque:3.5-4.5N.m
• Rated Current: 38A
• Net Weight: 3.6kg
• Length:128mm
• Diameter:108mm
• Chain Sprocket: T8F 11Teeth
• Shaft 11.75 mm
• Torque 3.5 to 4.5 Newton meters

Speed controller

Battery

6kg

Each Battery is 7.5cm wide and 18cm long Battery arrangement 150 mm width 180 mm length, will need some spacing around the batteries.

+-	+-
-+	-+

Battery charger

If we cant borrow one we will have to buy one

Brakes

Throttle Grip

Gear

Cabling

Some chunky cable to connect the batteries and motor.

Chain

Transponder

Suggested by hacky racing out of stock

Much cheaper compatible Weighs 20 grams

Fuse

Axel

Bearings

Tyres

Helmet

Battery Terminals

Pipe Clamp

Misc / screw

£3.00 wilko screws £26.55 petg plastic £8.01 Screws b&q £16.18 Foam, flux, screws £8.89 Nuts / bolts ebay £6.50 starlock clips £7.22 Bolts and bungie cord

Motor Mount / gearing

40 cm bar (no more then 20cm) to attach to frame 36.7 cm centre of holes either side looking at 50 to 60 teeth gear from the 11 tooth motor Current shaft is 11mm on the rear

Bill of materials

source gears 50 - 60 teeth figure out if we need a new shaft or if we can reuse the current one some how may need to weld.

Bill of material updated from above property draws

ITEM	STATUS	PRICE	WEIGHT	LINK
Parts		431.46000000000004	45620
Go kart frame	Recieved	25.00	17000
Motor	Recieved	93.90	3600	48v 1600w electric motor
Specs
Speed controller	Recieved	27.25	1000	48v speed controller 1500w
Battery	Recieved	126.20	24000	12v 20Ah battery
Battery charger
Brakes	Recieved	15.59	0	Bike disk brake
Throttle Grip	Recieved	3.99	0	Throttle Grip
Gear	Recieved	3.49	0	54 Tooth Gear
Cabling	Recieved	13.99	0	5m 42amp
Chain	Recieved	11.99	0	200 cm chain
Transponder	Not recieved	21.27	20
Fuse	Recieved	8.99	0	30A Fuse
Pipe Clamp	Recieved	3.45	0	8pc hose clip
Misc / screw	Recieved	76.35	0

Jobs

wire up motors speed controller and batteries

wiring for transponder lights horn ?

Weld rear axel and mount motor

Brakes

chain splitter screws about 5mm brush for space bus bar for connectors 13 mm shaft 10mm length charger crocodile clips drill 4.3mm / 5mm holes