HOMEMADE ELECTRIC BUGGY - CROSSKART - GO KART - Complete Build & Test Drive
Homemade Electric Buggy - Crosskart - Go Kart range test update: • Homemade Electric Bugg...
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: 102.4V, 14.7 kWh LiFePO4
Charging: 1 hour charge @ 1C max
Discharge: 3C continuous, 7.5C peak
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:
audiojungle.net/item/dark-rev...
'Cinematic Rock Trailer' by soundride:
audiojungle.net/item/cinemati...
VIDEO LINKS
Chassis: • Homemade Electric Bugg...
Suspension: • Homemade Electric Bugg...
Powertrain: • Homemade Electric Bugg...
Body panels: • Homemade Electric Bugg...
Battery: • Homemade Electric Bugg...
Seat and brakes: • Homemade Electric Bugg...
Cooling system: • Homemade Electric Bugg...
Dashboard and charge port: • Homemade Electric Bugg...
Limited slip conversion: • Homemade Buggy - Elect...
Paint: • Homemade Electric Bugg...
Wiring: • Homemade Electric Bugg...
Sheet metal brake: • Building A Sheet Metal...
Vacuum former: • Vacuum Former Build - ...
Tube Bender: www.kakaindustrial.ca/product...
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:
www.alibaba.com/product-detai...
300A Daly BMS:
www.aliexpress.com/item/10050...
F series charger:
kellycontroller.com/shop/f-se...
Website: www.resystech.com
Follow RST on Facebook:
/ renewablesystemstechno...
It looks like the Ackerman geometry is backwards in some clips, but I promise that's just an illusion caused by the wide angle mode that I'm using in the GoPro. Check out the suspension video on my channel for a clearer view of the steering geometry - I'm using close to 100% Ackerman. Update: the range test video is here >> kzhead.info/sun/etGdgtmQa3yfZHk/bejne.html
Yo I think it will be fly if you add wing tail and wings
few @@felixplaza1973 and Babb be there ittn a
@@robertscott3483 I don't understand what you are saying
@@felixplaza1973 Pot, meet Kettle.
@@NobbsAndVagene what this means
As an ex-metal fabricator, I have never seen such skill in one person. The buggy is incredible.
Maybe it's not in one person
@@pfauniversal1890 it’s one person. I know this guy. Grew up with him in my teens. Known him for 20+ years. Good friend of mine. He does it all himself. It’s nuts. He’s quite talented! The buggy was an idea among one of our friends and he brought it to life on his channel..
Yep , brilliant workmanship
I have to agree that I am a bigger fan of the fabrication he can do , well than say just the electrification. The factory finish level body panels, the welds, the design its all fantastic compared to a lot of pro You Tuber who may rush their stuff a bit more to keep churning out video's, you only see this come along rarely so Im really impressed.
he didnt list the weight of the vehicle
I love how this dude can make an electric buggy in a few months in his own garage that looks like something that rolled out of a factory. The talent of some people!
they say we are the only kind in the multiverse with the ability to create from thought to reality !
not only that but one that goes like 80 miles an hour. The stock Honda Suzuki that I own can only go 40 max
That's how they made cars back in the day, banging em out in a garage or old barn.
I think it looks even cooler than something that rolled out of a factory.
Mad Max vehicle goes electric? 😀
Instantaneous Admiration and Respect! I was on my University’s MiniBaja SAE team in college and we built a similar buggy for competitions. I know exactly how much work/effort/precision/skill goes into a build like this and you sir make it look EASY! Respect!! -CY Castor
True
Well done,....metalman.....you are a master craftsman...total talent .. you make it look easy with the beauty of creation. We all need to shift to evs as oil burners are killing our planet...with others help. But the fun and stealthiness of a fun fast ripper.....awesome build...
The amount of talent and knowledge shown here is incredible.
Real nice trick of using the welder to cut the stranded cable .. simultaneously cut and stop the fray. Perfect. Your skills are admirable. Amazing build!
Came down to say the same thing! Never saw (or ever even remotely thought about) anybody doing that before. Pretty smart!
Yup, doing this to bike brake and gear cables from now on...
Have to say credit for that idea goes to John Heiz - he shared the tip with me when I was installing the guy wires for my turbine tower.
@@JamesBiggar Well, if ya ever see him, tell him we say "thanks!" :D ..and thank you for passing it on!!
what time frame is it?
This vehicle is the ultimate form of the expression "BUILT, NOT BOUGHT". 👌🏼⚡❤️ So much love and attention to detail not only to the fabrication process but also the filming and editing throughout. Top notch work!
Now it is just missing registration? I saw that is possible in USA 🤓 ... in europe it would be impossible.. 😔
@@TheStuartstardust screw registration
@@TheStuartstardust such bummer... 😔
@@TheStuartstardust can do it in the uk not easy but possible
@@tonyw2960 not Europe anymore 🤪
The amount of work put into this is actually crazy! 🎉
Wow, this is one of the nicest self made buggies I have ever seen. I cant imagine how many hours you have into this project. You even built the batteries from individual cells. That alone is quite a project! I don't know how I am just finding your channel now but I'm subbed!
Thanks!!
Same here, don’t know how I’ve went so long on KZhead without these videos😔💯
If you need to plasma or gas cut sheet steel, mark it with an angle grinder cutting disc. You can see the groove through welding/cutting googles. Saves you a lot of grinding too. Awesome job!
@Busy right now Do you often make an ass of yourself?
It's actually a good tip
@@DopeyPotato That's what she said...
@@KermitOfWar phrasing!
@@KermitOfWar Kermit Army
What was the exact cost to make this electric buggy sir
A lot!
There's a lot of machinists and fabricators on KZhead but man you take the crown. Such an impressive display of several different areas of expertise. I'm completely amazed
All i can say is WOW. As a fabricator myself, you are a real mastor of the trait and a serious inspiration to anyone looking to fab anything. My hats off to you sir for this build. Your work is nothing shy of amazing and this is by far one of the best videos i have ever watched. Wow!!!
Incredible. I'm in awe of one person having the this level of skill in every portion of a build like this.
No question. If this were to be made available as a kit and given an instruction manual, I would buy/build this buggy. This thing is incredible. Great work! Do any of the other video do a cost breakdown of the materials? And another breakdown of potential labor cost?
That's exactly what I wanted to know too coming into the Comments hope someone answers
Same here
Well done. The simplest thing. When I saw you cut that coolant line, you went so far with the knife, and then began to use the tube for the rest of the cut. Right there . I see a man of Ingenuity and resourceful and a person that see's the value in production.
Awesome job. I can only imagine the huge amount of work behind this project, both in designing and manufacturing. You are an inspiration!
Really loved this build series, and am enjoying this summary with the extra voiceover now - almost to the actual driving section!
What an amazing video! One person, complete design, build, test, science behind the electrics, full understanding and explanation of mechanics, electrics, electronics and mechanical fabrication. Completely blew me away. Magnificent job, sir! Oh yeah, and the buggy's pretty good too!
This is an incredible display of skill and ingenuity. The fact that you also made a lot of the tooling you're using just adds to the resourcefulness.
Absolutely awesome James I don’t know what you do for a job but you need to be in research and development of electric vehicles and really taking your toys to market. I would definitely invest in you Awesome job
It's about having fun building something you enjoy, once it becomes a job it's no longer fun.
@@DespaceMan Very true.
100% to o% charge seems to be about 277 km range. So say in reality you use 80% down to 20% for battery life you get 166km of range depending on how much you flog it in the dirt with constant on/off power application. That's a great outcome! Well done. I didn't notice it in the video but do you have a chain guard in case that lets go and starts making mince meat of anything in reach?
I wasn't looking for this video, but I pulled an induction motor out of a dryer a while ago, and I've been itching to build something around it. I had all sorts of ideas rolling around in my head about the practical application of the project, and I settled for something road drivable but also offroad capable. I knew it had to have double wishbone suspension, but I was at a loss about how to lay it out. This video has been a very welcome inspiration. I'm saving it in a dedicated playlist for future reference.
Everything you did was top notch. From the metal working to the custom batteries. Even cutting the cable with the welder was genius. Beats heating it up and using solder.
So happy to see this finished. I want to make one too. I love the simplicity of the build, and the elegance of the design and math that went into creating it.
An awesome build! A little obsession of mine is putting the bolts always from the top. That way if the nut gets loose or even lost, there's a chance the bolt stays in place just by grace of gravity.
I grew up with my father running a welding and machine shop. I've been around some really smart machinist and welders that where capable of incredible builds. I've never seen one man with so much talent at the entire build ! Bravo and instantly subbed !
Thanks!
that final drone shot with the perspective on the distant forests got a big smile on my face. The one picture that captures the dream. Amazing built, also!
You make it look so easy, especially with pretty basic tools. It's easy to forget the skill that went into this. Looks super fun.
Thanks 👍
I'm very impressed by this build. The numerous and extensive skill sets you have are unbelievable! Well Done !!!!!
The way you filmed this with the commentary, was pure art
You made this look way easier than it is. Amazing build
So satisfying seeing all the parts coming together so well. Great work.
I saw many builds and I would say this is one of the best. I see knowledge, skills and last but not least well edited video. Very good job!
The professionalism, engineering and quality of your buggy is astounding .......words just don't do it justice
Crazy good fabricator and engineer! And the design is awesome! Good looking buggy too!
That was exceptional, i am impressed and jealous of your skills. What a cool creation! nice video work also, straight to the point and added commentary as required. cheers mate!
Awesome! I wanted to build something like this when I was in North Central PA and had only about a 5 mile drive to work on dirt roads, but you actually made it happen!
I've never seen some one work so quick and so precise. Badass.
This thing is brilliant, and incredibly well made. Awesome stuff!
From top to bottom, this is wildly impressive!! You should be very proud of yourself, sir! The build quality looks pristine!
This deserves a lot more attention!! beautifully shot, built, and edited! Amazing content sir!
The moment we've been waiting for. Congratulations on an amazing build. The buggy looks awesome.
This is beyond amazing! Thank you for everything
Cutting the wires with the welder is pretty neat.
I know NOTHING about metal fabrication or welding or how to build a Buffy from scratch. Watching this is truly inspiring, not only that but admirable. Your skill is top notch. Hats off 👏 Great build
Incredible build! (New subscriber here) I can't believe the effort, knowledge and talent that you put into this E-buggy! I thought of doing an E-buggy until I watched this. Since I have not one second of experience with any type of EV, I'd be lost. 😀 Thanks for sharing your amazing talents. I'm definitely going to check out the other videos on this build.
You Sir, I have mad respect for you and the whole process, well put together, well thought out, intricate skills, beautiful clean work of art right there. I’d like to work on my own project, and I’m definitely not on your level (wish I could be😅) but just an ATV, and seeing you putting everything together just motivates me even more. ❤
That much work from designing to collecting materials to fabricating all just in 30mins. Hats up to you. Buggy looks amazing. love from 🇮🇳
This is the most incredible thing i have seen a single person build and engineer. The editing is perfect too. I cannot express how much i enjoyed this video lol
Thanks!
Love this, beautiful frame, I see so many builds fall down at that very first step.
Thanks!
So well polished! Needs to start being mass produced and marketed!
IMHO, while you have nailed the looks 5000% it needs some form of gearing, cause the torque seems lacking or atleast.. underwhelming on low rpms.. But besides that, it is just GREAT!
Between the drive and driven sprockets and the final drive gearing in the differential, it already has gearing. 5:1, converting 99 ft-lb from the motor shaft to 500 ft lbs at the wheel. I can change it to whatever I see fit. 3:1, 8:1, 20:1. Just have to change a sprocket. What you're not taking into account is the power that I'm NOT using. Refer to the BMS app in the left corner of the video. I'm only pulling 245 A at 100V at the most = 24.5 kW. It can deliver 600A. I'm not even using half throttle, so if it seems sluggish, that's why. When you're testing a custom vehicle for the first time, it's usually best not to pin it to the floor and aim to kill it right out of the gate, especially not on public roads or trails. Gotta ease your way into it otherwise you won't collect as much information about how it performs other than how it died, or how you killed someone in the process. If you're referring to using a multispeed transmission, then no. That would be dead weight that just lowers efficiency. Transmissions are for ICE's because they lack low end torque. Comparatively, electric motors do not. It's all in the coil wiring. They produce max torque >100 rpm, by nature. An ICE doesn't reach max torque until at least 3000 rpm up to 10000, depending on the make/model. Multi-speed transmissions are a hinderance more than a benefit to ev's, that's why you won't find anything other than a single speed gearbox with forward and reverse in any of them. Tried, tested, and true.
I wish I had the right kind of mind to design stuff like this. There's just something special about driving a homemade machine. Can build RC aircraft, but this is on a completely different level! Absolutely awesome!
Excellent in every way! Your video production skills are awesome as well. I hope young people out there starting their electrical / mechanical journey purchase your plans and use it as a training course; or at least watch all of your videos to get an overview of how things can get done. Wow! Congratulations on your test run.
I'd want something like this as my daily driver, but one with road tires and more modern luxuries. Made for highways and such but capable of offroad, unlike "smart" cars. And it looks good. This is, like, the perfect form factor for me. I hate sitting off-center while driving. And I'm not a family man, I don't need a family car. I don't need room for four. May be a point to a slightly longer frame for a second seat in the back, but that's not entirely necessary.
take a look at the Ariel atom. may fit most of your desires except for center seating. they even make an electric version too. expensive though
@@jasonharrison25 The center seating is almost the whole point, so yeah the Atom does nothing for me Always interesting to learn about new vehicles though.
In awe of your technical, mechanical and sheet metal working skills - great work.
Awesome build James, thank you for sharing it with us!
She's a beast. Remarkable build, looks stable and fun to drive. Well done!
The buggy looks great, a very slick design. I also have to compliment your video and editing skills, your attention to production and fabricating details are next level.
Thanks!
Nice! People like you keep me motivated to tinker. I converted a cheap Chinese 4 wheeler to electric using dual 48v motors(each driving a rear wheel) a few years ago. It was fun but now I want to up my game and a project like this will help teach me to weld 😁
You are an absolutely amazing fabricator and engineer
James!!! You beautiful genius you! I loved every minute of this video. It was a welcome recap. Big kudos on the fluid and well delivered narration as-well. Now that it is drive-able, do you consider it finished, or are there some add-ons/modifications that you intend to make?
Thanks! I eat every bit of dirt and water the front wheels kick up so fenders are on the top of the accessory list. Some folks suggested a wing on the back to complete the crosskart look, others suggest using the back as a rack for a spare tire. Not sure which I'm going to do yet. A wing doesn't produce much downforce until around 80-100 km/h, so I need a good track to drive fast on and justify it (in the works). But >80km/h exceeds the speed rating for the atv tires that I'm using (part of the reason why I'm only using half throttle on the main road in the video and keeping it
@@JamesBiggar Fenders to divert puddle givings and other debris are certainly useful add-ons. So far as what to do with the un-used cargo space on the aft area, it really depends on what you are after. For me I wouldn't bother with a wing unless I knew the project was purpose built to perform in that kind of environment. A spare tire if even a tool kit would certainly be more useful in a time of need. You said you are building a track? We talking go fast and turn left (the dirt version) or something more rally inspired?
This is the single most amazing feat of engineering I can ever hope to see here on youtube. Amazing work as always!
If you think this is great should go check out the channel he got the blueprints from....
I'd like to see it too, because this is completely my design and I haven't published the plans yet. Took roughly 6 months in CAD prior to the year long build, and it changed 3 times during the process, all documented on my FB and blog. You can check out the evolution there. What I started with, which looked goofy af imo, and how I got to this point. There is no other electric crosskart like it, diy or otherwise. From what I've searched there's only one and it's manufactured for kids. Looks like it too. Tiny little thing, about half the wheelbase of mine. Does mine look like a typical crosskart? Yes, as do most karts. F1 cars resemble other F1 cars, super trucks look like other super trucks, etc. But mine is substantially wider than most in order to fit that 14 kWh bank around me, and that's part of what should make it an obviously unique and somewhat challenging design compared to others. But you're free to download the plans when they're available or take some screenshots from the video, scale them out and overlay onto the buggy you think I copied to prove me wrong. If just two pieces of tubing or any other two components match up in any way, I'll pay you $100. Let us know how you make out.
I probably won't get a notification if you respond with results, so hit me up at jbiggar@resystech.com. I'm serious. If you think I used someone else's design, prove it. I'll pay you and you get to tell everyone how you called me out and proved me a fraud :)
@@JamesBiggar Everything but being EV is a copy tube angles where you put the expanded sheet grid, bro even your dash board is a one to one copy. I'll go search through my watched list for the guy that sells the plans.
🤣 Riiight. That's hilarious. It's been 7 hours, what's taking so long? We're waiting. Compounding lies don't make them true. This isn't politics. Hurry up bro, let's see this buggy that I copied.
Amazing work! I've built race cars, rock crawlers, atv's, etc and the work you put into this was excellent.
Hands on engineer with incredible skills. Excellent design. I love your practical, and in budget choices.
BOI OH BOI HERE WE GO!
Loved your series, watched with my 6 years old that thinks you are a god :) Absolutely awesome build, the whole series is detailed and precise. My take: add some sound proof on the bigger panels to add some flex dampening too - it will cut the rattling and second hence this is off-road a bigger 3/6 teeth sprocket on the engine will add some extra umpf and faster acceleration. Love your stuff, what will you build next?
Thanks! A lightweight electric mid-drive enduro bike is next. I'm working on another big project atm to give this buggy a proper place to call home - it doesn't really fit with the electric theme of the channel but I'll probably post a build video when it's done too.
I could've sworn the buggy was fresh out of the factory. As a perfectionist, I feel so inspired watching this.
So organized. I love your method to your madness. I appreciate that high attention to detail. Great video!
This is an Incredible build !! Has to be one of the most difficult 1 man builds on the Internet.
That’s absolutely amazing! Great work! 👍🏾😎
Thanks Andrew!
WOW! This is just super cool. The skill to be able to build this blows me away. And the final product is is brilliant.
Man, that is some serious array of skills you've got there. Very impressive.
I don't know what is more amazing. The buggy or the MAD skills!
This is why youtube was made. REAL content and creator! I thought LiFe batteries were to heavy for mobile use... well that changed ;) great job
Incredible fabrication skills! You make it look easy!
It's so beautiful and has some kick! I been looking around on eBay and Facebook market for a used go-kart to convert to electric but never seem to find one that looks cool. You're custom made one blows pretty much anything I've ever seen out the market.
Wow, that's an awesome buggy! I want one! It looks very professionally built. The ride height seems more set up for track than off road, but I'm sure that can be adjusted. I'll bet it would be a blast on a paved track with slicks as well. Kudos!
This is amazing! This is what I dreamed of when building with lego as a kid.
Fantastic skills and knowledge of both fabrication and electrics
Seems like the algorithm has picked up this video, which is great because this is an excellent build. Well done.
My kind of guy. Everything you put into it, you made yourself. There is just a hard to explain satisfaction in building something from just a bunch of raw materials and basic parts.
The voice over reminds me of that guy who built that cabin in Alaska back in the day and filmed it all himself. Love it
I have built several electric vehicles, from the ground up. This looks like something a team of 6 engineers spent 3 years developing. Good job, brother.
This is the most satisfying build I've watched in a long time. You are very skilled sir!
videos like this are literally the best possible resume for you work... ever.
You're a legend man. The details, the skill, the simplicity that's awesome👍🏼👍🏼👍🏼
gorgeous work man! Super impressed by your craftsmanship and ev knowledge. found this video super inspiring!
I'm full of envy! the good one!, I wish I could make things like this by my self. I couldn't avoid to notice you strugling with that steering wheel design... I believe you have 2 options: A) Going back to design/functional basics with a regular round one, or B) Make the steering rack movement ratio bigger, that would allow you to turn more with less travel. Cheers from Argentina
Hi James , i was born in the 60's , made all sorts of stuff , choppers , E bikes , Kit cars , ,, But you sir ! are Amazing , the way you talk us trough your build is one of the best and relaxing i have seen in ages , Thumbs up and New sub .
Thanks! Glad you enjoyed it!
That turned out REALLY nice!! You do really nice work! GREAT job, and thanks for sharing with us!
What a amazing design so sleek modern sporty looking
I like to think of myself as a problem-solving, engineering type of person. This video makes me look like a toddler with finger paints. Nice work sir!!!
Awesome build and skills man! Thanks for sharing your talent to the world. You're an inspiration to those who dream to build these kinds of things like me !
Incredible. It's great to know "tinkers" still exist in the US. Well done sir.
James...!!! Esse seu Buggy é o MELHOR Elétrico que eu vi em todos esses Anos de novas Descobertas de Carros Elétricos...!!! Se eu tivesse condições. Compraria um Modelo desse...!!! Parabéns pelo seu Trabalho...!! Esta Realmente Maravilhoso, Awesome...!!
Incredible fab work. Fantastic electrical and beautiful finishing. Really well done
I just unliked it to LIKE it again.. Maaan! This was awesome to watch.
I am so jealous of your knowledge, abilities and techniques. I would love to have this for my son and me.
Incredible everything . Genius in every aspect of fabrication , and the electric is amazing …. All the buggy needs now is headlights taillights turn signals air conditioning and a stereo wow