Hi Endless Sphere,
this is my first post, i discovered this forum way too late, my first electric self build is finished by now
so anyways
working in grip and electrics (at the movies/TV) in a country where that business is not that much of a big industry i always envied colleagues in overseas that have golfcarts and utvs for transport and cool cameracars to mount stabilized cameras to.
like this:
or this:
because our industry is small we dont have trucks designated to carry polaris rangers or golf carts or anything like that around with us, i had to build something that fits into existing transport infrastructure of ours.
so if i wanted to carry less and drive more (and have the ability to mount stabilized cameras to my creation) and also be able to take it with me in existing transpo infrastructure, it had to be:
.)no wider than 80cm
.)no longer than 200cm (in order to fit a standard taillift)
.)no higher than 60cm (in order to fit into my estate car as well)
.)not too heavy (because lighting trucks surely dont have unlimited payload)
i must admit layout-wise i drew quite a bit of inspiration from classic taylor dunn carts (which i only knew from the interwebs):
but mine had to be roughly half the size of that.
a friend of mine whose a mechatronic engineer had an old electric motor lying around that he offered to give to the cause and also offered to help and another friend of mine whose an all around engineering/fabrication wunderkind also offered to help.
so we got cracking.
i knew i wanted a diff, because otherwise driving corners with heavy loads on conrete surfaces would be a pain.
i soon found a tecumseh lawn mower axle that was cheap and would still in pruduction if i ever needed spares.
so we cut the quad axle i bought in china (together with all the tires and the front suspension assembly) and cut the lawn mover axle:
and then joined them to one 80cm wide axle with differential:
then i started welding the rear swing arm, with my trusty 300euro flux core welder
and then ballparked dimensions:
ballparked gearbox and motor positions:
the gearbox also is a tecumseh lawnmover unit. costs like 80euros brandnew, is rated to withstand 15 horsepower (11kw), just like the diff.
it has 3 forward and one reverse gear (that proved useful later when using a wound field motor
one downside is that it is all straight geared, which males it a bit noisy.
the motor used to drive a hydraulic pump in a forklift. it is a brushed 80v 3000w unit.
sadly the output shaft was a bit shy:
so my friend threw this awesome thing together:
and the other one designed this:
after some more welding:
because of our cabover design, the steering would be the wrong way round, so one of my friends designed this:
and had it milled it at another friends place (the gears are off the shelf parts):
steering box (aliexpress utv steering box):
motor mount:
we go from engine to gearbox via toothed belt (because chains dont like to lie down and the gearbox has a vertical input shaft at the bottom) and then via chain from gearbox to diff/rear axle
after more welding:
after some more welding gases:
primed chassis:
test assembly:
finished, battery pack, 4x12V 50Ah AGM
the speed controller is a aliexpress 3000w pmw controller that cost 80buck, including a gas pedal, works fine so far.
finished wiring:
the LightRider has a 48v 10A charger built in
...and a bluetooth receiver and speaker:
as it has 48,3mm speedrail clamps built in, the finished product is rather modular,
here as an equipment Hauler:
or here as a moving platform for a stabilized camera:
oh, and the steering collumn is foldable, and then it does even fit in my car:
oh and heres a video:
https://www.instagram.com/p/B339pYRgxPT/
i hope you liked my lenghty post,
if you have questions or critique, hit me !
something i dont know much about is li-ion batterypacks, and i am a little afraid of them.
but my next project is gonna be a self built scooter with 2 hub motors and i wanna go li-ion on that one, so please expect lots of stupid questions from me.
(googling aliexpress battery pack experiences brought me here)
))
this is my first post, i discovered this forum way too late, my first electric self build is finished by now
so anyways
working in grip and electrics (at the movies/TV) in a country where that business is not that much of a big industry i always envied colleagues in overseas that have golfcarts and utvs for transport and cool cameracars to mount stabilized cameras to.
like this:
or this:
because our industry is small we dont have trucks designated to carry polaris rangers or golf carts or anything like that around with us, i had to build something that fits into existing transport infrastructure of ours.
so if i wanted to carry less and drive more (and have the ability to mount stabilized cameras to my creation) and also be able to take it with me in existing transpo infrastructure, it had to be:
.)no wider than 80cm
.)no longer than 200cm (in order to fit a standard taillift)
.)no higher than 60cm (in order to fit into my estate car as well)
.)not too heavy (because lighting trucks surely dont have unlimited payload)
i must admit layout-wise i drew quite a bit of inspiration from classic taylor dunn carts (which i only knew from the interwebs):
but mine had to be roughly half the size of that.
a friend of mine whose a mechatronic engineer had an old electric motor lying around that he offered to give to the cause and also offered to help and another friend of mine whose an all around engineering/fabrication wunderkind also offered to help.
so we got cracking.
i knew i wanted a diff, because otherwise driving corners with heavy loads on conrete surfaces would be a pain.
i soon found a tecumseh lawn mower axle that was cheap and would still in pruduction if i ever needed spares.
so we cut the quad axle i bought in china (together with all the tires and the front suspension assembly) and cut the lawn mover axle:
and then joined them to one 80cm wide axle with differential:
then i started welding the rear swing arm, with my trusty 300euro flux core welder
and then ballparked dimensions:
ballparked gearbox and motor positions:
the gearbox also is a tecumseh lawnmover unit. costs like 80euros brandnew, is rated to withstand 15 horsepower (11kw), just like the diff.
it has 3 forward and one reverse gear (that proved useful later when using a wound field motor
one downside is that it is all straight geared, which males it a bit noisy.
the motor used to drive a hydraulic pump in a forklift. it is a brushed 80v 3000w unit.
sadly the output shaft was a bit shy:
so my friend threw this awesome thing together:
and the other one designed this:
after some more welding:
because of our cabover design, the steering would be the wrong way round, so one of my friends designed this:
and had it milled it at another friends place (the gears are off the shelf parts):
steering box (aliexpress utv steering box):
motor mount:
we go from engine to gearbox via toothed belt (because chains dont like to lie down and the gearbox has a vertical input shaft at the bottom) and then via chain from gearbox to diff/rear axle
after more welding:
after some more welding gases:
primed chassis:
test assembly:
finished, battery pack, 4x12V 50Ah AGM
the speed controller is a aliexpress 3000w pmw controller that cost 80buck, including a gas pedal, works fine so far.
finished wiring:
the LightRider has a 48v 10A charger built in
...and a bluetooth receiver and speaker:
as it has 48,3mm speedrail clamps built in, the finished product is rather modular,
here as an equipment Hauler:
or here as a moving platform for a stabilized camera:
oh, and the steering collumn is foldable, and then it does even fit in my car:
oh and heres a video:
https://www.instagram.com/p/B339pYRgxPT/
i hope you liked my lenghty post,
if you have questions or critique, hit me !
something i dont know much about is li-ion batterypacks, and i am a little afraid of them.
but my next project is gonna be a self built scooter with 2 hub motors and i wanna go li-ion on that one, so please expect lots of stupid questions from me.
(googling aliexpress battery pack experiences brought me here)
))