How to Build Electric Riding Carts

Making an electric riding cart is an enjoyable activity.

An electric riding cart is an eco-friendly spin on a traditional activity that youth and adults have enjoyed in America for decades - soap box derby car racing. Youth teams, usually with adult helpers, can enjoy creating their own electric racing car and seeing how they perform against other each other in friendly competitions. Construct a lightweight body, fit it with wheels, brakes and an engine, and you’ll be well on your way to not only having fun, but maybe creating the electric car of the future.

Things You'll Need

• CAD software program
• Aluminum square tubing
• Steel rods
• Four wheels
• Steering wheel
• 2 bike caliper brake pads
• 24 volt motor
• 4 lead acid batteries
• Polyethylene foam sheets
• 2-part epoxy
• Fiberglass paint
• Waterproof sealant

Instructions

1. Use a computer assisted drawing (CAD) software program to create a template for your electric riding cart. Use the software to design a frame that is relatively basic and simple to put together, but that outlines the body, wheels, steering, brakes, engine and seat placement.

2. Build the body from aluminum square tubing since it is an excellent, lightweight material. Cut and construct the sides, front, back and bottom out of aluminum square tubing. Secure the joints on the body frame with aluminum plates connected by steel rivets to the aluminum tubing.

3. After constructing your frame, add the steering rod and wheel assembly to the electric car. Consider using two steel rods to run through the front and rear of the frame, which can then be bolted onto metal plates. Attach four wheels to the four metal plates on the sides of the car. Insert a steering wheel rod into the middle of the front rod. Connect the front and rear rods with an additional steel rod down the center bottom of frame so that turning the steering wheel allows you to turn all four wheels in the same direction.

4. Add bike caliper brake pads to the front wheels. Connect the brake tubing to the steering wheel rod. Connect a basic steering wheel to the steering wheel rod.

5. Power the electric riding cart with a 24-volt motor, such as the kind used to power wheel chairs. Connect the motor to a bike-style chain that wraps around the front passenger wheel rod so that when a gas pedal is pressed (either at the feet or on the steering wheel with the hand), the motor engages, causing the wheels to turn and move the car forward. Alternatively, if you prefer, enable the motor to be turned off and on with a simple switch that powers the car at one speed.

6. Power the motor with lead acid car batteries. Install two batteries on the front wheels and connect them to the motor.

7. Fill out the body of the car with polyethylene foam or thin plywood so that it is not an empty frame but a solid riding cart. Make sure you construct a bench seat so the driver is supported while operating the car. Consider that foam is much lighter than plywood and will enable the car to reach greater speeds. Use hot wire tools and metal rasps to shape the foam pieces you need for the body of the vehicle.

8. Glue the foam body to the frame with a two-part epoxy that will not melt the foam. Paint the car with colors of fiberglass paint that please you. Seal the foam with a spray or paint-on waterproof sealant to protect it and lengthen its life.

Resources

• Greenpower: A to Z Technical handbook Pdf