HOMEMADE ELECTRIC BUGGY - CROSSKART - GO KART - Complete Build & Test Drive

Homemade Electric Buggy - Crosskart - Go Kart range test update: https://youtu.be/GmdRuX4Ji1A

Hi folks. In this video I'm going to show you how I built my own electric buggy from start to finish, and how it drives. I set up chapters in the video so you can skip to the drive footage if you've already watched the build series. If you haven't seen the series yet, I linked to each episode below so you can check them out if you want more details. There's 10 episodes altogether, not including videos of the tools that I had to make along the way, so I had to leave a lot of things out of this video.

So, what can this machine do? Technically it's a crosskart, or at least inspired by crosskarts. It's a bit higher than most karts but a bit lower than most off road buggies. It only has rear wheel drive, so it's obviously not an extreme 4x4 or rock crawler. I wanted something to rip around my own private dirt track with, but isn't completely useless on the trails either. A universal play machine.

In terms of power, the motor is rated for 6000 rpm, can deliver 24 kW continuous and 55 kWp (72 hp), and 99 ft-lbs of max low end torque at a system voltage of 102V nominal. With the 22" Wanda tires and 5:1 gearing that I'm using, that translates to around 500 ft-lbs at the wheels and a top speed up to 120 km/h. For perspective, a Polaris RZR 900 buggy engine provides up to 88 hp and 60 ft-lb of torque, and has a top speed of around 100 km/h. In terms of powertrain performance, they're comparable.

I haven't tested the range of the battery yet, but will soon. A rough guess based on what we can see in the video, it should provide at least 100 km per charge with non-stop highway driving using constant power, although that's not what it's built for. On the trail I should get around 150-200 km per charge with the regen function operating more frequently (more braking = more charging). Similar to the 200 km range that the RZR 900 offers with it's fuel tank cap. Driving hard on a track, I'm assuming around 80 km/charge. Enough for a 40-80 lap race and more than enough for time trials.

SPECS
Power: 24 kW continuous, 55 kWp for 60 sec (72 hp)
Motor: ME1616 brushless IPM 3 phase AC
Max torque (at motor shaft): 134 nm (99 ft-lb)
ESC: Kelly KLS-8080N-NPS, programmable
Transmission/gearing: chain driven LSD w/ 5:1 gearing
Battery: 102V, 14 kWh LiFePO4
Charging: 1 hour charge @ 1C max
Range: 80-100 km on mixed terrain @ 60 km/h
Cooling: Active air and liquid
Regenerative braking
Electronic forward and reverse
Weight: 465 kg (1027 lb)
Wheelbase: 203cm (80")
Track: 160cm (63")
Ground clearance: 178mm (7")

Chapters:
0:00 - Chassis
2:53 - Suspension & steering
7:20 - Powertrain
8:20 - Body panels
10:55 - Bucket, harness & brakes
15:09 - Cooling system
17:12 - Paint
19:00 - Wiring
23:37 - Test drive

MUSIC
'Dark Revelations' by Overdrive Studios:
https://audiojungle.net/item/dark-revelations-slow/8353040

'Cinematic Rock Trailer' by soundride:
https://audiojungle.net/item/cinematic-rock-trailer-background/37990069

VIDEO LINKS

Chassis: https://youtu.be/QO7OHrW5oYM

Suspension: https://youtu.be/5Rd2FUzbS0I

Powertrain: https://youtu.be/W6elFcrIYBY

Body panels: https://youtu.be/kinq3E5XtHw

Battery: https://youtu.be/tL3TscrjgTA

Seat and brakes: https://youtu.be/O4Aaw649X6w

Cooling system: https://youtu.be/WYCuETxl5Rw

Dashboard and charge port: https://youtu.be/H8e--NJaFrQ

Limited slip conversion: https://youtu.be/_z0ByDjlHTI

Paint: https://youtu.be/4R_BrgWm0lM

Wiring: https://youtu.be/tdG0T_YbwRU

Sheet metal brake: https://youtu.be/eqpRH8Zflz4

Vacuum former: https://youtu.be/hdH8LSn1va8

Tube Bender: https://www.kakaindustrial.ca/products/kaka-tb-3-hand-pipe-bender-manual-pipe-bender

POWERTRAIN COMPONENTS

ME1616 motor, KLS96601-8080IPS controller with sin/cosine sensor, 600A main contactor, and throttle:
contact Fany to match and price at sales@kellycontroller.com

32650 LiFePo4 battery cells:
https://www.alibaba.com/product-detail/3-2v-lifepo4-32650-6000mah-battery_1600204982827.html

300A Daly BMS:
https://www.aliexpress.com/item/1005002554042155.html

F series charger:
https://kellycontroller.com/shop/f-series-charger/

Website: https://www.resystech.com

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