Go-kart
(Group Project)
Design Process
Our group will be following this design process to make our go-kart.
Research and Development
Inspiration Images:
Research:Â
https://www.instructables.com/How-to-Make-a-Go-Kart/ - A good layout on the process needed to make a Go-Kart!
https://www.homedepot.com/s/wheel%2520barrow%2520wheel?NCNI-5 - Missing one of the front wheels
https://www.popularmechanics.com/technology/gadgets/how-to/a6785/how-to-build-a-go-kart-in-one-day/?scrlybrkr=ea9cf69d - Little bit more on whatÂ
https://www.youtube.com/watch?v=vuRV-uXGy1w - Video by Colin Furze showing how to make a Go-Kart
Sketches
Top View
Steering System
Perspective
Drive System
Materials
We thought the rectangular aluminum tubing would make the chassis stronger and easier to put together.
Aluminum Rectangular Tubing
Go Kart Kit
4 Wheels
Steering Shaft
Front Wheel Axel
Turning Mechanism
Back Wheel Axle
Break System
Foot Pedal
Motor
Batteries
Seat
Machines
These are the many machines we plan to use to create our go-kart.
Timeline
(subject to change because of missing parts)
Week 1
Sketching, Research, CAD, Make Missing Parts Order
Week 2
Finish CAD and Start Chassis
Week 3
Assemble Chassis, Assemble Drive and Steering SystemsÂ
Week 4
Add Drive and Steering Systems
Week 5
Test Go-Kart System
Week 6
Finishing Touches
CAD
Chassis
Stellan - 2x1 Aluminum Rectangular Tubing, Bracket, Bracket Holes
Drive
Stellan - Sprocket, Brake Disc, Axle Mount, Wheel Mount, Castle Nut, Back Wheel, Full Assembly
Carter - Motor, Motor Sprocket,
Zach - Axle
Kasin - Axle Mount Bearing, Brake Disc Mount, Sprocket Mount, Castle Nut Spacer, Two Different Sized Spacers
Steering
Carter - Turning Mechanism, Steering Shaft
Zach - Steering Wheel, Cap Design
Kasin - Cap Body
Prototyping
Steering Wheel Cap
Our first two tries at making this cap did not go as planned. The first one printed as two separate pieces and was not strong. The second one did not have the correct infill which caused it to break easily. On the third try we finally got it!
T Brace
T Brace prototype I made for our crossbeams.
Assembly
Chassis
This is the base shape of our chassis. As we continued to work on the project, we added more cross beams and plates where needed.
Problems
While building the chassis, we had many problems with our brackets. The brackets we used had irregular holes that were slightly off-set and asymmetric. This made drilling hard because there was an odd pattern causing us to redo bars multiple times.
Back Axle On!
We attached the back axle and I tried sitting in it to find where we could put our steering system.
Front Wheels
Chair Bolted
Steering System
Our first problem was that the given parts for our turning mechanism were too long so we had to create our own. We also had difficulty welding this system but we were able to complete it and it works!
Drive and Brake
Both of these systems were not perfect, but we got them to function in time.
Fully Assembled!
We finally got the entire kart assembled and at the moment it works, but we will continue to work on it.
Test Drive
63573813438__AA28A9D3-ABC1-43E1-9E61-4C52A59C979F.MOVIMG_4325.MOVProblem Solving
Differential Drive
After many test drives, everyone agreed one of the largest issues was the turning radius. In an attempt to solve this issue, I decided to make a differential driving system, so the wheel not attached to the motor could spin freely. I mimicked the hub we had already been given and changed it a little and cut it out of steel.Â
