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  • 3 Speed Go Kart
  • Vector Controlled Rocket

Overview


My project partner and I decided to spend the summer working on building a 3 speed go kart. 


The goal of this project was to learn about all the different systems (brakes, chassis, transmission, etc.) and do our best to build a fully functioning go kart.

Prototyping

We spent the first 2 months simply acquiring, machining, welding, sanding and drilling everything together. 


For example, we welded the steering parts together as well as some parts on our transmission.


I also spent time planning different 3D printing arrangements to optimize strength but reduce printing time.

Initial Mock CAD of Transmission

This was the model that I created to help visualize how I would assemble the transmission, ensuring proper dimensions.


Additionally, this was the CAD model for all the 3D printing parts.

Failure

Our first iteration of 3D printed parts failed miserably and this was due to a lack in strength. 


In our 2nd iteration we switched to nylon and PLA+ with thicker print walls and density to increase strength.

Features

  • Designed chassis and steering.
  • Implemented brake, gas pedals and clutch.
  • 3D printed transmission system.

Video of go kart running in 3 different transmission gear ratios.


Our second iteration worked well in comparison to the first. I believe the most beneficial change was increasing wall thickness and switching the highest stressed part to nylon as it it the best material for non-metal gears.

Results

  • Due to 3D printed transmission, we had a very limited life span before the parts were destroyed. 


  • Everything else functioned perfectly, we were able to stop and start, steer and sit comfortably.


  • Our method of shifting gears was too difficult to use while driving.


  • Had a relatively low top speed due to limitations from 3D printed parts.

Unfortunately this was all the footage I was able to gather as the metal key responsible for transferring the rotational power shredded my gear. This rendered it useless.

More Images

Conclusion

This project taught me a lot about the different aspects of motor vehicles. It gives me a lot more appreciation to actual vehicles and the intricate details you have to put in order to make it last a long time. 


I plan to use this general experience and apply myself into a more specialized project next time. Instead of being a jack of all traits and building a full object, I want to specialize in one thing and optimize it.


Special thanks to Puneet Dhaliwal for his help on this project. 

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