Devlog #2: More CAD and design changes

What I did

The majority of the time I spent for this devlog was just CAD, but a decent part of it was googling and asking ChatGPT questions.

Powered wheel module (PWM)

After finishing the frame and starting the front steering/powered wheel module, I realized that welding my own steering fork that could hold a motor and the wheel would be both expensive and turn out crappy. After doing research on alternatives, I came across the hub motor wheel: an expensive but much simpler and more compact way to power my kart. With the hub motor, I would no longer need to chain a motor with a wheel, which would’ve been many moving parts that I would need to maintain. Pairing this with a commercial e-scooter front fork, it would save me tons of headache with gearing, chaining, welding, etc. To add on another benefit, I already own an e-scooter frame with a head tube that is compatible with the front fork I am planning to get.

Drift bar mechanism

After solidifying my plans for the PWM, I started designing the drift bar mechanism. The Razor Crazy Cart drift mechanism consisted of one big pipe in the back, supported by two pillow block bearings, with the caster wheels, hardstops, and a compound lever all welded on. However, I want to minimize the amount of welds I need to do for this project as my access to a welder is quite limited. After doing some research, I came across the single socket tee: a pipe fitting that allows me to attach pipe perpendicular to the main back pipe with set screws. Since set screws are pretty weak, I also plan to use through-bolts with lock nuts for additional strength. Using this, I can have one rotating main pipe on the back and securely attach the two casters, hardstops and a drift lever (which I’ve modified to just be a simple second-class lever.)

What’s next

I hope to finalize the entire CAD next and create a BOM so I can submit this project for funding.