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How to Make an Electric Go Kart

By austiwawa (/member/austiwawa/)
in Workshop (/workshop/) > Electric Vehicles (/workshop/electric-vehicles/projects/) 261.729 1.013 79 Featured

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(https://content instructables com/ORIG/F1M/M6QG/J1QPB6D9/F1M

auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=8a310c7
(https://content instructables com/ORIG/FJ8/STTD/J1QPB63A/FJ8
 How to Make an Electric Go Kart by austiwawa (/member/austiwawa/) Follow Download
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auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=81a604e180f6f0fca7cf2815728a00ec)
(https://content instructables com/ORIG/FXR/V73E/J1QPB6LP/FXRV73EJ1QPB6LP jpg?

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By austiwawa
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About: Hello and welcome! My name is Austin. I enjoy creating interesting projects and sharing my projects and ideas with
all of you. Please feel free to check out my Youtube channel: https://www.youtube.com/user/aus…
More About austiwawa »
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In this Instructable I will be showing you how I transformed an old gas powered go kart into an
electric go kart. This project was very time consuming and I am very happy to finally share it
with all of you! The hardest part of this project was definitely searching for all of the parts and
overcoming issues along the way. This go kart is loads of fun to drive around town and with the
current sprocket set up it can go around 50kph!

Before you go through the rest of the steps for this project, you should definitely watch the
video that I have posted below. The video will show you plenty of clips of me building the go
kart from start to finish and you will also be able to see my drive it! Also, if you enjoy the video
you should definitely hit the like button or even consider subscribing to my YouTube channel.
Most importantly don't forget to follow me here on my Instructables page so that you can see all
of my future projects! Let's get started with this project!

https://www.youtube.com/watch?v=6_zB5_nKqIc
  Add Tip V Ask Question
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Step 1: Buying an Old Go Kart

auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=57e8d5e
(https://content instructables com/ORIG/F5S/X10I/J1QPB9A1/F5

auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=fc1767b
(https://content instructables com/ORIG/F0B/YDHF/J1QPB9BN/F0

auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=bde8a6e5dbe4c9bcf7a23767fe429e7c)
(https://content instructables com/ORIG/F3M/5JUP/J1QPB970/F3M5JUPJ1QPB970 jpg? auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=b0ac0a
(https://content instructables com/ORIG/F8G/NSL3/J1QPB9CD/F8

A while back I was browsing through Kijiji and I came across a rusty old go kart which I ended up
purchasing for only $60! This go kart did not run and was overall in very rough shape. All that
mattered was it had a lot of the parts that I needed in order to complete this project. I had the
 How to Make an idea ofGo
Electric making
Kart by an electric
austiwawa go kart for quite Follow
(/member/austiwawa/) some time and when I sawDownload
this go
kart Favorite
for sale
w
I knew
I Made It

it would be the perfect time to get the project started.

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Step 2: Restoring the Frame

auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=c01c2c7
(https://content instructables com/ORIG/FAL/EDWO/J1QPBL45/FA

8 More Images
auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=a44d2e15d5bfb676ac7681fca2f83ec4)
(https://content instructables com/ORIG/FXG/B3TF/J1QPBKXJ/FXGB3TFJ1QPBKXJ jpg? auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=fa16abed
(https://content instructables com/ORIG/FZD/X7J2/J1QPBKJ7/FZ

I spent a lot of time restoring the frame along with some of the original parts. I started by
disassembling the entire go kart. The frame was very rusty and all of the old paint was peeling
off. The first thing I wanted to do was grind the frame down to bare metal in order to prepare it
for a new paint job. After removing all of the rust I realized that the frame was very short and
because I am 6' 2" my legs would not fit comfortably. I ended up cutting the frame in half and
extending it by 5".

Once that was finished I gave the frame a fresh coat of paint and then slowly began putting the
go kart back together. The paint I used was a vibrant orange Rustoleum oil based paint.

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Step 3: How It Works

How to Make an Electric Go Kart by austiwawa (/member/austiwawa/) Follow Download
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auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=500969
(https://content instructables com/ORIG/FZ9/WPQ7/J1QPBPIC/FZ

3 More Images
auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=1e35fe
(https://content instructables com/ORIG/FKQ/UKWZ/J1QPBPJD/FK

Before I go any further with this Instructable I am going show you all of the parts that I used and
show you how everything will work.

The parts that I used were:

A 1600W 48V brushless motor

A 1600W 48V speed controller
A 48V hand throttle with a battery indicator and speed limit switch
 A 3 pole
How to Make an Electric charge
Go Kart port (/member/austiwawa/)
by austiwawa Follow Download
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A key switch
And a 48V 12AH lead acid battery pack

I would have much rather used lithium ion, but that would have made things much more
expensive.

In the pictures above you will see a diagram that I made so that you can see exactly how I wired
everything together.

The motor, speed controller, hand throttle, charge port, battery charger, and batteries were all
purchased from: http://www.hyperpowersports.com/categories/electric-scooters/parts-for-hy-
per-racing-1300/electric-scooter-parts.html
(http://www.hyperpowersports.com/categories/electric-scooters/parts-for-hyper-racing-
1300/electric-scooter-parts.html)

You can also find most of these parts on Aliexpress.

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Step 4: Making the Foot Throttle

auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=8ae1ee
(https://content instructables com/ORIG/FX8/CXY1/J1QP9MJR/FX
How to Make an Electric Go Kart by austiwawa (/member/austiwawa/) Follow Download
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9 More Images

One of the first things that I did was convert the hand throttle into a foot throttle. I started by
disassembling the throttle and removing the battery indicator, as well as the speed limit switch. I
will be re using the battery indicator later on but I won't be re using the speed limit switch.

I then took some measurements and designed a foot pedal on Tinkercad which I then printed
using black ABS. The pedal just slides on and is fastened into place with two screws. I then
covered up the existing holes so no dust will get inside and added a spring to give it more
tension. I also added a stopper so the pedal can't get pressed too hard and snap.

Here is a link to the .STL file: http://www.thingiverse.com/thing:2248293

(http://www.thingiverse.com/thing:2248293)

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Step 5: The Build

auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=633327
(https://content instructables com/ORIG/FJI/C0VX/J1QP9PIX/FJ
How to Make an Electric Go Kart by austiwawa (/member/austiwawa/) Follow Download
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33 More Images

Here are some pictures of me assembling the go kart so you can see how I put everything
together.

The original rear hubs were seized onto the 1" live axle. I was forced to cut them off with a
grinder and look for new ones. Luckily my neighbor had some old wheels in his shed so I took
them apart and cleaned them up. Originally these hubs had bearings inside and were not made
to go onto a live axle. What I did was removed the bearings and welded on some weld on hubs
from Princess Auto.

The seat that originally came on the go kart was broken in half. The new seat is a LEIFARNE seat
shell from IKEA and it works perfectly!

I used Molex connectors to connect all of the electrical components together. All of the
electrical components get connected to the speed controller. The speed controller is fasted
inside of a 6"W x 8"L x 3"H aluminum project box. On one side of the project box there is a
flexible grommet which all of the wires can be fed through. The other side of the project box is
where I fastened the charge port. On top of the project box is where I put the key switch as well
as the battery indicator. I put heat shrink around the battery indicator to avoid any short circuits.

The go karts brake is a simple disc brake which is connected to a foot pedal at the front with a
length of threaded rod.

The sprocket on the motor is a 12 tooth sprocket and the sprocket on the axle is a 61 tooth
sprocket. The chain size is #35. The sprocket on the motor is custom made. I welded a 12 tooth
sprocket from princess auto onto the T8 sprocket that came with it.I ran the motor and held a
flap disk to it in order for the outer diameter of the old sprocket to fit inside of the new one. That
way it could be welded on perfectly straight.

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Step 6: Things to Know

How to Make an Electric Go Kart by austiwawa (/member/austiwawa/) Follow Download
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auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=998a966
(https://content instructables com/ORIG/F8U/9HLH/J1QP7NN7/F8

3 More Images
auto=webp&frame=1&width=1024&height=1024&fit=bounds&md=31a540f
(https://content instructables com/ORIG/FXO/7YLX/J1QP7NNA/FX

Overall I had a lot of fun building this go kart and it works better than I expected! Although
there are some features that can be added. One very important thing that I am missing is a chain
guard.

I have yet to determine how far it can go on one charge (I will update this when I know). I only
drive the go kart for about 20 minutes at a time. I do this just to allow the motor to cool off.

Also, for better results try to keep the weight of your go kart as light as possible. This will result
in better performance.
How to Make an If you have
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Go Kart by questions please feel free
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I hope that you all enjoyed this Instructable! Don't for get to follow me here on Instructables and
to Subscribe to my YouTube channel! Thanks for reading and watching :)

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79 Comments

(/member/RivL714/) RivL714 (/member/RivL714/) 16 days ago

on Introduction Reply / Upvote
Hello, I recently found this post and was very intrigued but unfortunately I wasn't able to view the video
you posted showing the build. The video is currently listed as private, would you be so kind as to grant
me access to the video please and thank you 😊

(/member/NathanC176/) NathanC176 (/member/NathanC176/) Question

3 years ago
on Step 6

Answer / Upvote
can you use a 2000w 48v brushless instead of a 1600w?
1
answer
F

(/member/NathanC176/) NathanC176 (/member/NathanC176/) Question

3 years ago
on Introduction

Answer / Upvote
How much would you spend if you used a 2000w 60v brushless and lithium battery?
1
answer
F

/2 (/member/bobox911/) bobox911 (/member/bobox911/) Question

2 years ago Answer / Upvote
Could you add a speedometer to it? If so, then how?
1
answer
F

(/member/Prem456/) Prem456 (/member/Prem456/) Question

2 years ago
on Step 4

Answer / Upvote
 Can it ran with 250w 24 v ? if yes than at which speed?
How to Make an Electric Go Kart by austiwawa (/member/austiwawa/) Follow Download
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1
answer
F

(/member/cars+cars+cars/) cars cars cars (/member/cars+cars+cars/) Question

1 year ago

Answer / Upvote
can you use a 1800 48v brushless motor
2
answers
F

/1 (/member/sniperprince.vandan/)
sniperprince.vandan (/member/sniperprince.vandan/)
Question
1 year ago
Answer / Upvote
what site did u take it from ?? im too looking for a racing body under 100$

1
answer
F

(/member/gashis2018/) gashis2018 (/member/gashis2018/) Question

1 year ago

Answer / Upvote
could you please give a tentative budget you had for this endeavour.....if you could also give the price
for the frame it would be really helpful
1
answer
F

(/member/SilvestriLuke/) SilvestriLuke (/member/SilvestriLuke/) Question

1 year ago
on Introduction

Answer / Upvote
I was wondering what gauge of wire you use for all of this
1
answer
F

(/member/jameslrob101/) jameslrob101 (/member/jameslrob101/) Question

1 year ago

Answer / Upvote
I was wondering if you had any trouble with wheels slidding when turning?

(/member/titas1533/) titas1533 (/member/titas1533/) Question

1 year ago
on Step 2

Answer / Upvote
How wheel you use?

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