Go Kart From Malachi Parks Point of View (Period 1, Green team)

For this Project, Kelsey, Joey, Alex, Aly and I are assigned to make a Go-kart that is drill powered. We were supplied only one piece of plywood to make our whole Go-kart design fit onto.

Inspirational Designs

The these two designs are the same essentially just from different perspectives. This Go-Kart had inspired us to make a steering system with a lever rather than a wheel for design ease.

The seat in this photo is the basic idea that we all agreed on to make. The sides would snap into the base as the seat piece would snap onto that.

Crucial Decision for the Team

This is Shear's racing stats from when he races Go-Karts in his free time. Among being the lightest of all of us too, we designate him to be the driver of the Go-Kart, therefore this Go-Kart is designed around him.

Design Phase

Body

Our Body was inspired off of the photos we had seen online plus the model Go-Kart that Estock had shown his classes. Originally we decided to do a chain driven wheel system on the back with two wheels. Later on though for simplicity the team decided one wheel would be an easier design to manage. The location of the front wheels is housed withing the cut piece of plywood which is 48in. by 12in.

Seat Triangles (Snap-Together)

For the snap together requirements, the seat had been designed with support structures which will snap into the base. Illustrated above is the dimensions of the seat completed with maximum size that we can have with the seat without shooting over the length of our body design.

Seatback

Naturally without a seat back the design of the snap together triangles is pointless. Designed by Shaer, the seat back was made so he can sit at a slight angle while driving to obtain complete comfort.

Throttle

Changing designs for our throttle, we decided that it would be easier for us to make a indirect drive instead of the chain. The drill would be housed in something that would be able to move down, held in place by the tension of the spring when the pedal is hit, and would move out of the way when the pedal does not have pressure applied to it.

Braking

Braking was meant to run under the car, (shown in Onshape later on) when the brake is hit, a piece of wood would slide back and apply friction to the back driving wheel to slow down the Go-Kart. Up above the blue tape marks out where the system will be.

Steering

Rather than column driving, a lever, when moved forward would turn the front wheels to the left/right due to its position and do the reverse when pulled backwards.

OnShape Information

Onshape is a online free CAD software that can be used to accurately model parts. From here, you can export the items you make in Onshape as an STL, Parasolid, etc.

For this project it was required for each member of the team to create an individual piece of the Go-Kart. Once each person was done, it had to be assembled in a assembly.

OnShape Designs

Illustrated above are the models that all of us had created in Onshape. Joey made the steering lever and housing for the front whee (top left 2)l, Aly made the base (top right), Shaer made the seat back (bottom left), Kelsey made the triangle (biggest picture of them all) and I made the braking system (middle left of the triangle).

Assembly

Above is the finished product of what the Assembly looks like in Onshape. The seat and triangles are fixed while the front wheel housing turns on a 39 degree angle at most. Overall it took the whole team a class period to create this fine model.

VCarve Information

VCarve is used to Shopbot through pieces of thick wood such as ply wood. Think of it as the laser, but instead it uses a rotary bit to cut through the wood when given certain tasks.

The video above is a brief introduction to Vcarve and its capabilities once mastered.

VCarve Files

Instead of taking snapshots after snapshots of VCarve step by step Shear and I decided to snapshot the final product of the tool-path. The inside pieces were done in the first order then all of the outside pieces were done right after. Of course, we had added Dog-bone fillets on the mortises and tenons so the snapping together would be seamless.

3D representation of how the tool-path will look once it is shop-botted

The button above is how we got from step A-Z, following the steps from downloading our PDF from Onshape to scaling each piece up and joining their vectors.

More or less this is what the Onshape PDF looked like that we used for VCarve

Shopbot Set-Up

Prior to being able to Shopbot our pieces, the team had to secure the piece of plywood to with screws. While this was happening I had opened the Vcarve file to print the file once everything was in place.

Shopbotting in Progress

As seen above, the Shopbot was mid way through cutting out our pieces such as our seat supports and our main body.

Assembly of the Seat

Above are multiple shots of the seat being assembled after we had taken our piece off of the Shopbot. Yet, this is only half of the seat made as you can see the other side of the rest is not fixed yet.

"Clean-up"

Shaer holding one of the pieces that we had remaining after scraping down our piece of plywood to pieces of wood that we could use.
Here is what remains of our Plywood once we had chopped it down to fit in the garbage cans in the shop.

Assembly of Body

To ensure the body remains stable under the weight of Alex, we ran a piece of plywood underneath the car to reinforce it. The goal was so the piece of our plywood would not bow under the weight of our driver.
This image above illustrates where we will have our wheel attachment will go. The white piece, while not attached yet is a piece of guide wood to ensure the string for our acceleration does not get in the way of the driver.

Assembly of the Driving System (Currently in Progress)

Before we have made our Drill housing, I had set up the gear settings for the drive train. Above are all the settings so I would not forget them if I had to remake the gears.
After numerous errors, I had gotten the file to render correctly in Vcarve. I found if the gear had more than 36 teeth, it would do a lap around the outside of the gear twice, thus reducing the piece to a circle at best.

Attachment of Wheels (Currently in Progress)

To the right is our 72" inch rod used for our axle. We had just gotten this Thursday because of the snow storm on Tuesday, canceled school. On the table are the springs we are using for the pedals so they return to the correct position.
The piece above is our main attaching point for the front wheels. The blocks of wood that Shaer and I attached are to ensure that the axle remains in place as the wheels turn.
Unsure of where our long rod went, even though i'm positive we put it away correctly, is gone. Thus we had switched to half an inch thick dowel rods because they don't get stuck as easy and rotate smoothly through the holes for our support.

*Disclaimer* Due to horrible time management and a lack of things wanting to work when need be, we are behind schedule!

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