FACULTY: FACULTY OF MECHANICAL ENGINEERING

 
PROGRAM: BACHELOR OF ENGINEERING (HONS) MECHANICAL (EM222)
 
COURSE: MEC 435 (COMPUTER AIDED DESIGN) 

LECTURER: DR FREDDAWATI BINTI RASHIDDY WONG

MINI PROJECT OF ELECTRIC GO KART

PREPARED BY

NAME STUDENT ID GROUP

BARTIMEUS ANAK TINGGI 2022838836 EMD3M4D

MUHAMMAD IKHWAN BIN ANUAR 2022830536 EMD3M4D

ABDULLAH FAYYADH BIN KAMARUZAMAN 2022830582 EMD3M4D

FAIZ HAIKAL BIN JOHARI 2022830678 EMD3M4D

ADAM ASYRAAF BIN SAHUL BAHARI 2022838828 EMD3M4D

TABLE OF CONTENT

Title Page
LIST OF FIGURES I
LIST OF TABLES II

1. INTRODUCTION
0
1.1 Project Definition
1.2 Problem Statement
1.3 Project Objectives

2. JUSTIFICATION OF CHOOSEN / REASON

0
2.1 Literature Review

3. JUSTIFICATION OF PRODUCT CHOSEN THROUGH DESIGN

0 MORPHOLOGY
3.1 Defining Problem
3.2 Gathering Information
3.3 Concept Generation
3.4 Evaluation of Concepts

4. MODIFICATION / INNOVATION / COMPLEXITY

0
5. THE MANUFACTURING PROCESS
0
6.0 DISCUSSION

7.0 CONCLUSION

REFERENCES

APPENDICES

LIST OF FIGURES
 Figure Title Page
2.1 Statistic on causes of death in Malaysia
2.2 Malaysian citizens percentage
2.3 First ever Go Kart
2.4 Eco-Diy Go Kart
2.5 Eco-Diy Go Kart
2.6 Electric Go Kart

LIST OF TABLES

Table Title Page

3.1
3.2
3.3
 5.1
5.2
5.3

1.0 INTRODUCTION 

1.1 Project Definition

The go-kart is a lightweight, quick, manoeuvrable, and small vehicle. The go-kart lacks
suspension and has very little ground clearance compared to most cars because it is made for
flat-track racing. A go-kart consists of an engine, chassis, steering, suspension, tyres, shaft,
gear, battery, pedal throttle, and bumpers. Either a two-stroke or a four-stroke engine powers
a go engine kart. A vehicle with electric motors rather than an engine is referred to as an eco-
kart. Go-karting is a form of open-wheel motorsport that involves lightweight, open-wheeled
vehicles with four wheels. The chassis is independent of the suspension to feel the
excitement.

Go-karting is the ideal outlet for racers due to its simplicity, low cost, and safer method of
racing. A track could be either indoors or outdoors. Compared to F1 tracks, go-kart tracks are
much smoother. The experience of driving a go-kart will better prepare the driver for the
environment of real racing, enabling them to compete as a professional motor racer in
different events. The goal of this project is to design and build a go-kart that is lightweight.
Therefore, it can lessen the overall weight of this vehicle by selecting an appropriate material
for its construction.

1.2 Problem Statement

The problem statement of this project is:

(i) To improve the skill and knowledge of Mechanical engineering student in designing and
importance of project developing go-kart.

(ii) To build a lightweight go-kart

1.3 Project Objectives

This small project was carried out to increase consumers' awareness of the importance of

living a healthy lifestyle. The study's specific objectives are ;

1. To design the mechanical product by using CATIA software.

2. Selection of a suitable material for designing

3. Analysis of Go-Kart on Finite Element Analysis

2.0 JUSTIFICATION OF PRODUCT CHOOSEN / REASON

Go-karting is an exhilarating, fun-filled activity that we can enjoy with friends, family, and
co-workers. Aside from being an absolute blast of adrenaline and awesomeness, go-karting
also improves your confidence, reflexes, strength, and stamina.

Besides that , many people today lead sedentary lifestyles, which puts them at increased risk
for developing serious conditions including high blood pressure and diabetes. The effect, it
harms the people’s health and snatches away an individual's tranquillity. To boost
productivity, people must adopt a healthy lifestyle to avoid the problematic lifestyle.
In addition, in this mini project of Go-kart there are several mechanicals principles which is
gear, shaft, driveshaft and chassis.

Figure 2.1

According to Figure 2.0, Malaysian citizens have a higher percentage (17%) of ischemic
heart disease than pneumonia (11.4%) and cerebrovascular disease (8.3%) [3].
One of the risk factors of ischemic heart disease is a high blood cholesterol level. 

Cholesterol can constrict the human artery which makes the area of the artery smaller. The
blocked artery will cause a heart attack that damages a heart muscle caused by the shortage of
blood and oxygen.
 Figure 2.2

According to Figure 2.1, Ischaemic heart diseases remained as the principal causes of death,
17.0 per cent of the 109,155 medically certified deaths in 2020. This was followed by
Pneumonia (11.4%), Cerebrovascular diseases (8.3%), Transport accidents (2.9%) and
Malignant neoplasm of trachea, bronchus and lung (2.5%).

2.1 Literature Review

2.1.1 Benefits of Go-Kart

Activities like go-karting are very beneficial in lowering the risk of sickness in other people.
Go-Karting activities have a lot of benefits such as strengthening reflexes. Go-kart tracks had
been set up with various lanes, twists, and turns. This situation is the perfect configuration to
improve people’s strength and reflexes. While driving the Go-Kart, all the twists and turns
will force the driver to navigate the Go-Kart to avoid bumping into other drivers. 
 
Moreover, Go-Karting can boost people’s adrenaline. Drivers will become delighted as the
track's light turns green during the race. This situation is called adrenaline which increases
heart rate, expanded airways and dilation of the blood vessels. Adrenaline also helps to
increase energy and memory.
  
Furthermore, Go-Karting can build stamina. Stamina improvement occurs in people’s bodies
caused by endurance. Also, people’s bodies need a lot of stamina especially at our hand’s
section such as biceps and triceps. For example, all muscles will be sore when the driver uses
the kart's steer to maneuver all turns and twists.

Lastly, Go-Karting can help boost the reaction time of the racer. This is due to the fast-paced
nature of go-karting. Because of this, excellent racing on the track and competing against
other racers both need rapid reactions, quick thinking, and quick decisions. For example
when two Go-Kart racers approach each other at the corner situation. The racer behind needs
to react fast to shorten the distance of the front Go Kart racer. He also needs to be very
focused during that time and have quick decision-making abilities in case his choice to
minimize the distance proves to be a mistake.

2.1.2 First Ever Go-Kart

The first ever Go Kart was invented by none other than Art Ingels. He is known as the
‘Father of karting’ as he builds the first ever Go Kart. Art Ingels is a race car builder at Kurtis
Kraft which was an American designer and builder company that specializes in building
Midget cars, quarter midgets, sport cars, sprint cars and son on so forth. 

Figure 2.3
The first-ever go-kart was constructed by Ingels in 1956, with the help of Lou Borelli. They
used for the build a West Bend 2-cycle 750 engine taken from a lawn mower, slapped it on
top of an incredibly simple tubular chassis and adorned the entire machine with semi-
pneumatic tires.
Officially, this go-kart has no name but is known in the world of kart enthusiasts as Kart No.
1, or The West Bend. The engine developed only 2 horsepower, delivered to the left rear
wheel through a countershaft constructed of bicycle chains, sprockets, and a centrifugal
clutch.

Braking was achieved by using a pulling lever fitted on the right-hand side. The lever pivoted
a plate which pressed a braking pad against a disc welded to the right rear rim.

This first kart was rarely used in racing, but when it drove Ingels himself to and fro, it
managed to attract a lot of interest. The first public appearance of the model took place the
same year, at the Pomona sports car races.

2.1.3 Eco Diy Go-Kart

Go-kart is a small car that is used for recreational and competition purposes hence the design
needs to be convenient and user-friendly for all drivers. After doing some research, there are
lots of go-kart designs on the market. However, some can say that all of the go-kart designs
use plastic seats and the seat is fixed. Figure 2.1.3.1, Figure 2.1.3.2 and Figure 2.1.3.3 show
different designs but with the same inner part.
 Figure 2.4

Figure 2.5

2.1.4 Electric Go-Kart

As time goes on, both Go Kart and technology improve and become more contemporary.
Previously, a go kart could only reach a maximum power of 25 hp, but as technology
advanced, go karts could now reach speeds of up to 140 miles per hour and they could even
go faster, but only at the expense of the driver's safety and other factors like materials and
aerodynamics.

There are several different varieties of go karts available nowadays. there are 8 classes of Go
Karts and the difference between them is their cc, top speeds, age of racer, types of engines
and their use such as for professional use or casual use. Racer’s age can be as early as 8 years
old and for a certain Go Kart class, a minimum requirement of 32 years of age is required to
drive the Go Kart.

The electric of Go Kart can also be recognized by not only the change of the engine, but it
can also be recognized by the shape of the Go Kart that boasts aerodynamics and multiple
breakthroughs through engineering design and multiple testing.
 Figure 2.6

3.0 JUSTIFICATION OF PRODUCT CHOSEN THROUGH DESIGN

MORPHOLOGY

3.1 Defining the problem

3.1.1 Product Design Specification

i. Product design identification

a) Aerodynamic and aesthetic design

b) Function ;
 - enable driver to compete as a professional motor racer

c) Special Feature

- unique chassis

- hole at bucket seat of driver to make more comfortable

- made of strong material for long-lasting product

ii. Market Identification

a) Market size : 10/50 units/year

b) Branding strategy

- build a new brand for electric go-kart

-use internet platforms such as website, socmed and online shop (Instagram,shopee)

-brochure

iii. Key product deadline

a) Finish time : 7-8 month

iv. Physical description

a) Dimension : 2023.11mm x 1249.06

b) Material : steel, plastic

c) Load capacity : 136kg max

d) Estimate weight : 75/79kg

v. Financial Requirement

a) Time to complete project and key project deadline : 3-5 months

b) Warranty Policy : 1 year

c) Retail Price : RM5000-RM10000 and free maintenance for first 6 months

vi. Life Cycle Target

 a) Lifetime : more than 20 years if well maintenance

b) Cost of Installation and Operation : none

c) Maintenance Schedule and Location : Every 6 months at certified branch of hardware

d) Reliability : Anti Corrosion coated with paint

e) End life strategy : End user can recycle the product by sending it to the manufacturing
factory

vii. Social Political And Legal Requirements

a) Standards Pertinent Product Standard are applicable such as OSHA

b) Safety and product liability

c) Predictable unintended used for the products, safety label guidelines, applicable
company safety standards

3.1.2 Benchmark for Go kart

Table 3.1

Design 2 Design 3

Design 1
Aerodynamic Modern and
Good with basic Good features but
Innovative feature
features but less low stability due to
that provides more
aerodynamic material
aerodynamic.
Performance Excellent due to Good performance
the multifunction as a standard go Good performance
and more powerful kart but less as a mid go kart but
to move comfortable at less powerful
bucket seat
Stability Phenomenal
Great average
stability due to the Excellent stability.
stability.
wide body.
Price Affordable for its Affordable for its
Average Pricing:
functionality: RM functionality: RM
RM 900- RM 2000
5000-RM7000 4000-RM 7000
Material Steel Stainless Steel Stainless Steel

3.2 GATHERING INFORMATION (Product’s function and features)

3.3 CONCEPT GENERATION (Morphological Chart Tools)
Table 3.2

Components Option1 Option 2 Option 3

Chassis

Steel Stainless Steel Hard Plastic

Bucket Seat

Carbon Fibre Hard Plastic Leather

Wheel

Hard Tyre Medium Tyre Soft Tyre

Steering

Car
bon Fibre Aluminum Cast Iron
Gear

44 tooh 48 tooth
50 tooth

Pedal Throttle

Steel Plastic Steel with non-slip

Paddle Brake

Steel Plastic Steel with non-slip

Battery

12V 3Ah 12V 12Ah 12V 4Ah

Motor

36V 48V 60V

Shaft

Solid Shaft
Hallow Shaft

Design 1
Design 2
Design 3
3.4 EVALUATION OF CONCEPT (PUGH CHART)

Table 3.3

Description Standard Gokart Design 1 Design 2 Design 3

Sketch

Criteria Weight Datum Design 1 Design 2 Design 3

Weight 1 0 + - +
Comfort 2 0 + + -
Safety 3 0 + - +
Ergonomics 3 0 + + +
General 1 0 + 0 +
Aesthetics
Durability 1 0 + 0 +
Life 1 0 + 0 -
Expectancy
Material 1 0 + + -
Eco-Friendly 1 0 + + +
Design
Price 1 0 + - 0
+ 15 5 9
0 0 0 0
- 0 -5 4
NET SCORE 15 0 5

+ Good
0 Par
- Bad
4.0 PRODUCT MODIFICATION

In this mini project, there are some modifications that we made to improve our go-
kart more powerful and good in all aspects. Many of these adjustments and improvements
can be made quite quickly and are not as difficult as they seem.

Upgrade the size of driveshaft

The driveshaft receives power from the engine, which is the heart of the go-kart. The go-kart
accelerates as the wheels spin as a result of the driveshaft's connection to the axle. You may
easily replace the engine in your go-kart with a more powerful one if you want it to have
more power.

Install a supercharger / high voltage

A supercharger or a turbocharger can be installed in a go-kart that the builder is designing

themselves. Due to the fact that both parts have forced induction systems, the air that enters
the go-kart engine is compressed. More fuel can be burned if more air is allowed to pass
through. The fundamental distinction between these two parts is that the crankshaft of a
supercharger provides power, whilst the exhaust system of a turbocharger provides it.

Re-gearing the go kart

In comparison to the kart engine, this will result in more wheel and axle revolutions. In
general, the go-kart moves faster the more axle and wheel revolutions are made. Keep in
mind not to go overboard. The kart can cause the engine to put too much force on the axle by
switching to a sprocket that is too small or has too few teeth.

Lightweight body of go kart

Possibly the simplest piece of advice for making your go-kart quick is to make it as light as
possible. Keep in mind that a go-kart will accelerate more quickly than one with a lower
power-to-weight ratio. This means that they might try to boost the power of your go-kart by,
for instance, installing a supercharger or improving the engine. The go kart can try to alter the
other side of the equation, though, by trying to lighten up.
Increase the size of tires.

Greater force can be transmitted to the ground by using larger go-kart tyres. All of the energy
in the driveshaft is transferred to the axle, then from the axle to the wheels. The go-kart
moves more quickly and with less force when there is more surface area between the tyres
and the ground.

5.0 THE MANUFACTURING PROCESSES

A manufacturing process is one of the important processes to produce a product that has
quality and is valuable in the market. The manufacturing process can be defined as a
procedure used to change raw materials into a finished product. Designing, sketching,
assembly, and analysis are a few examples of these processes. The main parts of  GO-Kart
had been experienced the process below: 

Table 5.1

NO PROCESS DESCRIPTION PICTURE

1 Sketching Profile & Constraint

2 Sketching-Based Shaft
Features
Pad

3 Dressing-Up Edge Fillet

Features
 Table 5.2

NO PROCESS DESCRIPTION PICTURE

1 Sketching Profile & Constraint

2 Sketching-Based Pad
Features

3 Dressing-Up Edge Fillet

Features

Edge Fillet

Pocket

Table 5.3
NO PROCESS DESCRIPTION PICTURE

1 Sketching Profile & Constraint

2 Sketching-Based Pad
Features

Edge Fillet
 3 Dressing-Up
Features

6.0 DISCUSSION

7.0 CONCLUSION

The goal of this project was to construct a go-kart based on a conceptual design that had been
optimized to improve the vehicle's stability. The Go kart’s design and fabrication are focused
on creating a simple, lightweight, and simple-to-use vehicle. Ergonomics, safety, and
reliability were all factors considered in the design specifications. All major components
were examined in order to improve vehicle performance, strengthen and rigidify the vehicle,
and reduce complexity and manufacturing costs.

In conclusion, an Go-kart can increase people's productivity by providing exercise equipment

that can help the user live a healthy life because the design and modifications in this project
can benefit the users. Based on this mini-project, design. By utilising Catia Software, the Go-
kart can expose students to improve critical thinking in problem solving through product
innovation. As a result of the presence of this product, consumers' minds may be opened to
the importance of living a healthy lifestyle in order to save people from high-risk illness.

8.0 REFERENCES

1. “China ATV Manufacturer, Go Kart, Golf Cart Supplier - Yongkang Fourstar Co.,

Ltd.” Chfourstar.en.made-In-China.com, chfourstar.en.made-in-china.com. Accessed

26 Jan. 2023.

2. Department of Statistics Malaysia. “Department of Statistics Malaysia Official

Portal.” Www.dosm.gov.my, 16 Nov. 2021, www.dosm.gov.my/v1/index.php?

r=column/cthemeByCat&cat=401&bul_id=R3VrRUhwSXZDN2k4SGN6akRhTStw

QT09&menu_id=L0pheU43NWJwRWVSZklWdzQ4TlhUUT09.

3. “Gk2g (Electric Go Kart).” Coroflot, www.coroflot.com/designbybeau/Gk2g-electric-

go-kart. Accessed 26 Jan. 2023.

4. “Go Kart History, What Is Go Karting - Pole Position Raceway.”

Www.polepositionraceway.com,

www.polepositionraceway.com/blog/what-karting/#:~:text=In%20the%20beginning

%2C%20the%20first.

5. Health Fitness Revolution. “Top 10 Health Benefits of Go Karting.” Health Fitness

Revolution, 7 May 2015, www.healthfitnessrevolution.com/top-10-health-benefits-go-

karting/.

6. https://www.facebook.com/KartFab. “Go Kart Plans | Download Free PDF -

KartFab.com.” KartFab.com, 13 Oct. 2019, kartfab.com/go-kart-plans.

7. Patrascu, Daniel. “A Short History of Go-Kart Racing.” Autoevolution, 27 May 2018,

www.autoevolution.com/news/a-short-history-of-go-kart-racing-125891.html#agal_1.
8. “Technology News, Latest Technology News, Gadgets News.” BGR India,
 www.bgr.in/news/xiaomi-launches-ninebot-gokart-kit-that-converts-its-self-

balancing-scooter-into-a-go-kart-672768/). Accessed 26 Jan. 2023.

9. “The Difference between Gas & Electric Go Karts.” Tampa Bay Grand Prix, 15 Jan.

2020, tampabaygp.com/blog/gas-versus-electric-go-karts/.

10. “Top 10 Health Benefits of Go Karting - Adventica.” Www.adventica.lv,

www.adventica.lv/en/news/top-10-health-benefits-of-go-karting-94. Accessed 26 Jan.

2023.

11. World, Motor. Why Go-Karting Is Good for Your Health | Welcome to Motor World

Virginia Beach. vbmotorworld.com/go-karting-is-good-for-your-health/.

12. CHAUHAN, A. (2016). Design and analysis of a Go-Kart, International Journal of

Aerospace and Mechanical Engineering, 3,9.
13.

8.0 APPENDIX

8.1 Finite Element Analysis

8.2 Complete CAD Drawing
8.3 Part Projection Drawing
8.4 Assembled Drawing
8.5 Bom Exploded View Drawing