GoKart Nolan schaeffer

Day 1: The top picture is our base design, once we finished brainstorming and later made the seat on Onshape and assembled it. On Onshape I create mortise and tendons to snap the pieces together. There is also a CNC

The next step after Onshape was to start construction. Together we built the structure for the front wheels based on our white board sketch.

During the construction process, Colin worked on turning signals, horn, and throttle with the Arduino.

Day 4: Everything came together on the fourth day. The base was built, the seat was CNC'd, and we started to work with the wheel we purchased. The structure of the Kart was built by 2x4's and the ShopBot was used to make the very specific pieces with specific dimensions like the seat.

We continued working with the wheels. We worked with a thread rod and finished the assembly of the front wheel piece. The little piece in the middle of the frame has a little hole in it because that is where we are going to attach the body frame. This will allow rotation.

Here we connected the front wheel base to the main base of the Kart, and the last picture os the start of our braking system.

This is a picture of the final brake, it is pulled by a rope and causes friction on a wheel attached to the spinning thread rod acting as the axil.

Very surprisingly, we had our Kart built very quickly. The entire structure was built already, so all we had to do was work with the wheels and transmission. We are still adding additional parts like steering and transmission.

We now have the brake attached to the frame of the kart and now we are starting to work with the transmission and how we can change speed while driving the GoKart.

Here is where our team stands currently, brake is complete, frame is strong, and seat is assembled. Now we need to finish the steering and the transmission.

Moving on to the console/dashboard, we mounted the arduino setup underneath this piece of would to prevent from the wires being messed with when working on the GoKart. We have a kill switch, turning signals and a potentiometer to control speed using a servo.

Here is the transmission that we have constructed. It has 3 levels of speed and it can be changed by a shifter. As of now we have problems with the lack of tension to allow the gears to lock teeth. To resolve this problem, we added a spring so increase tension and to keep the shifter in a set position.

We had trouble with the steering, we figured this handle would be the best design. We used the lathe and created a smooth surface and 3D printed 2 triangles for extra support.

Here I 3D printed a led/turn signal holder. I measured the width of the wood to create a snug fit. This allows the turn signals to be on each side of the car in clear vision.

To power the kart, we tied a string around the trigger for the drill and connected it to a wheel so when the servo is activated, the string tightens to start the drill.

Next we built the braking system, we followed the concept of the steering but just made the lever pivot. A string runs underneath/through the car and is attached to the brake that was made earlier.
Now that breaking and steering are complete, we made a holder for the drill and since the servo and the wheel broke so many times during testing, we added an axil to increase the strength.

I decided to make a license plate for the car while we had some down time. We are in the process of spray painting it so the letters can be black.

This is the spray painting process of the license plate. We coated the luan 3 times and let it dry before lasering it. When it is done lasering, the wood should contrast with the black paint to create readable letters.

This is the finished product of the license plate. It turned out perfect.

This was a new addition I added to the car. Don brings coffee every morning so I decided to make cup holders.
I laser cut them to fit the exact dimensions of his coffee cup and added another just incase he brought a friend along for the ride.
The initial gear started to shred so we created a new one out of oak for more strength.

We had to start the transmission basically all over again due to the break.

We continued to fix the gears and reduce slop to create a clean and smooth ride.
We added metal bracket support to reduce slop and this helped significantly.
We created a support for the transmission hold on the lathe. This added extra support so the entire rig doesn't shake as much during the drive.

The battery kept dying very fast, so we made our own 9v source.

We are still working out the kinks with the source of power. The drill continues to overwork itself and we cant drive for long.

Final Stretch

During the last couple weeks we basically just went over the top. We were done with our kart so we added an air cannon to it for fun.
We decided to change our transmission from our previous 3 gear system (left pic) to a one gear direct system (right picture). This switch reduced the slop and increased the stamina of the drill battery and the kart's ride.

Colin took it upon himself to make the entire gokart wifi controlled. It took 35 minutes...

RACE DAY

Our gokart starts off very strong. It doesn't require any push or momentum.

This was our final test. We angled the gokart so it could go as far as possible without hitting any walls. It reached the end.

Problems

Our axil wasn't completely straight during the process of testing, therefore the gokart drove at an angle instead of straight. We had to curve the gokart from the start point so it could reach the maximum drive length.

Steering

We had a problem with the teamwork between the driver and the pusher...

This shot was the best thing that happened that day.

Problems

Our kart couldn't steer with certain amounts of speed and the entire steering process was stiff and hard to control, especially at high speeds.

BRAKING

The first test did not work very well. Our brake wasn't alined and wasn't tight enough to have friction to stop the wheel.

On the other hand, our gokart is designed to brake on command. It is wifi controlled so we just command a kill switch to the program and it stops instantly.

Problems

The brake never really alined with the axil so it was always out of place. The brake also need a ton of force to work efficiently.

In conclusion, our Gokart was out of this league but it was a fun project.

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