HOMEMADE ELECTRIC BUGGY - CROSSKART - GO KART - Complete Build & Test Drive

Hi folks. In this video I'm going to show you how I built my own electric buggy from start to finish, and how it drives. I set up chapters in the video so you can skip to the drive footage if you've already watched the build series. If you haven't seen the series yet, I linked to each episode below so you can check them out if you want more details. There's 10 episodes altogether, not including videos of the tools that I had to make along the way, so I had to leave a lot of things out of this video.

So, what can this machine do? Technically it's a crosskart, or at least inspired by crosskarts. It's a bit higher than most karts but a bit lower than most off road buggies. It only has rear wheel drive, so it's obviously not an extreme 4x4 or rock crawler. I wanted something to rip around my own private dirt track with, but isn't completely useless on the trails either. A universal play machine.

In terms of power, the motor is rated for 6000 rpm, can deliver 24 kW continuous and 55 kWp (72 hp), and 99 ft-lbs of max low end torque at a system voltage of 102V nominal. With the 22" Wanda tires and 5:1 gearing that I'm using, that translates to around 500 ft-lbs at the wheels and a top speed up to 120 km/h. For perspective, a Polaris RZR 900 buggy engine provides up to 88 hp and 60 ft-lb of torque, and has a top speed of around 100 km/h. In terms of powertrain performance, they're comparable.

I haven't tested the range of the battery yet, but will soon. A rough guess based on what we can see in the video, it should provide at least 100 km per charge with non-stop highway driving using constant power, although that's not what it's built for. On the trail I should get around 150-200 km per charge with the regen function operating more frequently (more braking = more charging). Similar to the 200 km range that the RZR 900 offers with it's fuel tank cap. Driving hard on a track, I'm assuming around 80 km/charge. Enough for a 40-80 lap race and more than enough for time trials.

SPECS
Power: 24 kW continuous, 55 kWp for 60 sec (72 hp)
Motor: ME1616 brushless IPM 3 phase AC
Max torque (at motor shaft): 134 nm (99 ft-lb)
ESC: Kelly KLS-8080N-NPS, programmable
Transmission/gearing: chain driven LSD w/ 5:1 gearing
Battery: 102.4V, 14.7 kWh LiFePO4
Charging: 1 hour charge @ 1C max
Discharge: 3C continuous, 7.5C peak
Range: 80-100 km on mixed terrain @ 60 km/h
Cooling: Active air and liquid
Regenerative braking
Electronic forward and reverse
Weight: 465 kg (1027 lb)
Wheelbase: 203cm (80")
Track: 160cm (63")
Ground clearance: 178mm (7")

Chapters:
0:00 - Chassis
2:53 - Suspension & steering
7:20 - Powertrain
8:20 - Body panels
10:55 - Bucket, harness & brakes
15:09 - Cooling system
17:12 - Paint
19:00 - Wiring
23:37 - Test drive

MUSIC
'Dark Revelations' by Overdrive Studios:

'Cinematic Rock Trailer' by soundride:

VIDEO LINKS

POWERTRAIN COMPONENTS

ME1616 motor, KLS96601-8080IPS controller with sin/cosine sensor, 600A main contactor, and throttle:

32650 LiFePo4 battery cells:

300A Daly BMS:

F series charger:

Follow RST on Facebook:

[cincinnatusromanus]

As an ex-metal fabricator, I have never seen such skill in one person. The buggy is incredible.

[TorQueMoD]

I love how this dude can make an electric buggy in a few months in his own garage that looks like something that rolled out of a factory. The talent of some people!

[christophercastor]

Instantaneous Admiration and Respect! I was on my University’s MiniBaja SAE team in college and we built a similar buggy for competitions. I know exactly how much work/effort/precision/skill goes into a build like this and you sir make it look EASY!
Respect!!
-CY Castor

[pixelspring]

Real nice trick of using the welder to cut the stranded cable .. simultaneously cut and stop the fray. Perfect.
Your skills are admirable. Amazing build!

[djbis]

This vehicle is the ultimate form of the expression "BUILT, NOT BOUGHT". 👌🏼⚡❤️
So much love and attention to detail not only to the fabrication process but also the filming and editing throughout. Top notch work!

[longbow]

I wasn't looking for this video, but I pulled an induction motor out of a dryer a while ago, and I've been itching to build something around it. I had all sorts of ideas rolling around in my head about the practical application of the project, and I settled for something road drivable but also offroad capable. I knew it had to have double wishbone suspension, but I was at a loss about how to lay it out. This video has been a very welcome inspiration. I'm saving it in a dedicated playlist for future reference.

[namesgamby]

There's a lot of machinists and fabricators on YouTube but man you take the crown. Such an impressive display of several different areas of expertise. I'm completely amazed

[Mpnavy]

If you need to plasma or gas cut sheet steel, mark it with an angle grinder cutting disc. You can see the groove through welding/cutting googles. Saves you a lot of grinding too.

Awesome job!

[wilsoncharles]

All i can say is WOW. As a fabricator myself, you are a real mastor of the trait and a serious inspiration to anyone looking to fab anything. My hats off to you sir for this build. Your work is nothing shy of amazing and this is by far one of the best videos i have ever watched. Wow!!!

[motosker]

Wow, this is one of the nicest self made buggies I have ever seen. I cant imagine how many hours you have into this project. You even built the batteries from individual cells. That alone is quite a project! I don't know how I am just finding your channel now but I'm subbed!

[cnjmargeson]

The amount of talent and knowledge shown here is incredible.

[BobDurelle]

Absolutely awesome James
I don’t know what you do for a job but you need to be in research and development of electric vehicles and really taking your toys to market.
I would definitely invest in you
Awesome job

[valkyrieedit]

No question. If this were to be made available as a kit and given an instruction manual, I would buy/build this buggy. This thing is incredible. Great work! Do any of the other video do a cost breakdown of the materials? And another breakdown of potential labor cost?

[mihaiturc]

Awesome job. I can only imagine the huge amount of work behind this project, both in designing and manufacturing. You are an inspiration!

[leightonwestbury]

The professionalism, engineering and quality of your buggy is astounding just don't do it justice

[alexmaclean]

Incredible. I'm in awe of one person having the this level of skill in every portion of a build like this.

[IVIaskerade]

This is an incredible display of skill and ingenuity. The fact that you also made a lot of the tooling you're using just adds to the resourcefulness.

[SurRonDude]

The amount of work put into this is actually crazy! 🎉

[GingerPiston]

Really loved this build series, and am enjoying this summary with the extra voiceover now - almost to the actual driving section!

[Ambrjack]

What an amazing video! One person, complete design, build, test, science behind the electrics, full understanding and explanation of mechanics, electrics, electronics and mechanical fabrication. Completely blew me away. Magnificent job, sir!
Oh yeah, and the buggy's pretty good too!