as long as we can see the same expression on your face, that’s fine!
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Mcmaster hardware came in today and I am ready to start moving on more physical parts of this project. @BluPenguin should receive the battery soon and am excited to see what they do
My to do list is as follows:
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get dimensions together and get the “trucks” / “steering knuckles” cut from Sendcutsend.com so I can weld them up when I have access to the facilities at school again.
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Work on the open source DAVEGA code and try and tie it into the Teensy doing the throttles and throttle input light bars… maybe try and add a reverse switch as well (low priority)
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create CNC file for the weird rig I have to make for the bent maple deck.
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cnc foam for deck and enclosure
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epoxy and vacuum bag deck pieces
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final design and 3D print handles, joystick caps, loop key/charger/microUSB port and speedometer screen bezel (Using formlabs tough resin)
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trace the final shape, measure a couple of times and drill/cut once!!!
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finish and poly all the wood
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fiberglass enclosure
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spray paint or powder coat the welded parts?
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FINAL ASSEMBLY!
- we are taking pictures! and driving some parking lots!
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UPDATE:
Sendcutsend get me my design for the back to me within 3 days and for a decent price.
Gotta get access to the welder now and melt them all together.
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hahah fun to see who is behind the “madman who built a kart with maytech hubs”. Always wondered if there was a post about it. Cool stuff man 
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It’s coming along. One day I will just be folklore.
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Decided to post this here as well as on the cheap and free thread.
update, I just bought them from a different vendor with free 2 day shipping
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Finished doing the modeling of the handles and joystick “caps” … so time to print them!
Using Form Lab “Tough” resin. Hopefully have them printed by the end of the week. I designed them to hold the joystick PCB’s and bolt into the laser cut metal center part of the wheel.
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So awesome man, just read the entire thing looks so fun !
Nice job on the design too !
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The actual design aspect was kind of put to the background of function and form but I think bent plywood and speed are pretty darn cool myself
I think it will be awesome when it is a completed object and all the electronics are integrated to an enclosure, there will be very little that makes it look like it should move a grown man at 30mph or accelerate the way it does. I am so excited to get the deck built and have a curve
The battery is coming back to me tomorrow from getting reconfigured by @BluPenguin and got 2 more P groups so it is now 10s7p in a layout that allows for it to fit in the enclosure in the renderings. More info on it tomorrow when I receive it and stop drooling.
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Battery came back from @BluPenguin land! I am digging the clear shrink wrap and the communication allowed for us to chang from my original plans for a 10s6p stacked configuration to a 10s7p staggered with the BMS on the top.
Battery is now 10S7P and charge only BMS. This is a tiny cube of lightning!
I will now be able to boost the regen and actually have max power to the motors.
The battery will sit flush on the new “deck” and the motor wires will come up through the deck in front of the battery with the esc’s on top of or in front of the battery. Whatever works, I will have to tighten up my harness but that is little fish.
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UPDATE!
resin 3D printers are awesome!
Got the handles, joystick caps, bezels for lights and screen all back today.
Now I am finishing up the setup and final wiring for the @janpom ‘s Davega OS setup…
But I need help
I cannot get it to show data even with it wired correctly and my Baudrate @ 115200 bps and the controller set as PPM and UART
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Goofed around with the code and still can’t get it reading anything. Tried other firmware, tried updating the esc, tried stuff I didn’t even know what it was changing… tried some more. Still can’t get it to read info off of the esc. I think it is Arduino side because there are TX and RX LED’s and they aren’t blinking when it is powered on…
It was never part of the design to have a screen but now that I am so close, I really want to get it working!
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Got it working!!! It was the firmware. I had to downgrade to VESC fw3.48 to get it to work.
*Still have to go back in and edit the number of poles in the code to the proper amount.
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Just been through the whole thread, amazing work man. Seeing the process like this is great.
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This weekend the buck is getting created and the deck is getting made!!!
Deck is going to be 9 plies (6 long grain plies and 3 cross grain) and then top and bottom will get a beauty veneer to hide the zig zag butt joints of the long grain plies.
Got materials for the deck bending jig, and the enclosure build. Unsure if I want to build the enclosure mold out of foam and build it from the inside > out, or out of MDF and build it from the outside > in.
This is the template for the deck jig.
I am currently also looking into how I can condense all the electronics I have.
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Would have been a hell of a lot easier if I could have CNC’d this MDF but 2 days with a jig saw and it’s done. Haven’t fought like that on something for awhile… I’m sore, but I won. Giving myself the day tomorrow to focus on other projects before prepping the veneers and actually making the deck.
Feel like a coach builder now with this buck/jig made.
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Yeah !! Well done, its gonna be beautiful !
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Holy shit I miss the facilities at school! My last week of progress has been so slow because I was doing it the Amish way without CNC’s or lasers. Hoping the human elements won’t ruin the final outcome. Almost said f*ck it today and gave up… drank a beer and am back at it trying to get it done!!!
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THAT WAS A FIGHT! and I am sure it’s not going to come out quite as planned I just hope it is solid and gives me something to work from. The “wings” were a much bigger pain than first imagined. The back rest mounting will have to be tweaked. But that will be thought of in 15 hours when I can take this thing out of the vacuum bag as see what I actually have created… hopefully it isn’t just an expensive piece of bent fire wood.
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Wings were a fail. It was my first ever attempt at anything like this so I am trying to stay positive. I have some ideas already for what to do about that though as I am going to make a buck for the back rest soon and can adjust my plans accordingly.
Overall it is very solid with the 6 long grain and 3 cross grain layers. I flipped it upside down and put all of my weight on it with little to no flex.
Tomorrow I will trace out the shape and cut out the rough shape, prior to sanding the top and bottom smooth and rough cutting the 8’ face plies of Maple I have for the top and bottom to cover up the zig zag joints I had to do. Basically fix it to look right and cover up all the ugly.
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