Homemade Electric Buggy, Ep 1: Steel Tube Chassis

Homemade Electric Buggy, Ep 1: Steel Tube Chassis

In this video I begin building my homemade electric buggy/crosskart. Crosskarts are basically large, powerful go karts that are typically raced on dirt and ice rally tracks, sometimes also called ralley karts. I'm not a pro racer, so mine will be designed with a bit more ground clearance for ripping up the off road trails around my home instead, and will sport a 55 kW (74 hp peak) electric powertrain consisting of a liquid cooled ME1616 IPM motor from Motenergy, a KLS96601-8080IPS controller from Kelly Controller, and a custom built 102V/14kW LiFePO4 battery.

A breakdown of how I made the chassis and with what materials can be found at my blog:
https://renewablesystemstechnology.com/project-blog/building-an-electric-crosskart-the-chassis

Crosskart specs:

Motor - 55 kW (74 hp) liquid cooled Motenergy 1616
Battery - 96V, 9.6 kWh LiFePo4
Controller - Kelly KLS96601-8080I/IPS sinusoidal wave
Transmission - Chain drive w/ Honda CR-V limited slip differential, CV axles
Wheelbase - 77" (196 cm)
Track - 60"
Suspension - front & rear independent double wishbone w/ coil over shocks, 8" (200 mm) travel
Ground clearance - 10" (280 mm)
Wheels & tires - 22x7-10 front, 22x10-9 rear, Wanda sport tires

Tube notcher build video: https://youtu.be/a4zL720_EDo

Electric motorbike build:
https://www.youtube.com/watch?v=gYs_jYUyaoY&t=6s

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