Bram Loren Metalworks
My senior capstone is converting a an off-road buggy I bought online from gasoline to electric power. Engineering has been a passion for as long as I can remember. When I was brainstorming capstone project ideas 6 months ago, I knew I would do something related to engineering, I just hadn’t figured it out yet.
Eventually I decided on this project. This fused both my knowledge of engineering, and areas I wanted to improve my understanding in, like electronics and controls. When I am completed, I will have a trail-worthy cart that is more capable and versatile then the original gas-powered cart.
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Over the course of the project I will be restoring the suspension, brakes, steering column, and seating of the cart. I will also repair all the rust on the cart, and then re-finish and re-paint the steel tube-frame. The primary component of the project is fitting a completely electric drivetrain and battery system into it. This will not only make the cart more environmentally friendly, but improve its capabilities off-road with all of the benefits of electric motors.
The cart when purchased, with all original equipment still mounted
Rear view of original cart
Cart after most of the junk was torn off, and the frame was pressure washed to remove any loose dirt and mud.
Original combustion engine still mounted inside the cart
All of the junk removed from the cart
Soaking components in white vinegar overnight to remove surface grime and rust
Painted steering components ready to be
re-installed
Repainted and degreased front suspension back on the cart
New brake system ready to be installed on the kart
Current state of the cart
Some of what was removed initially from the cart. Includes fenders, wiring harness, foam, etc
Original engine after being removed from its mounting points in the rear of the cart
Rear view of the cart, now with no engine
Steering column of the cart removed
Masking tape on components to be repainted
Restored steering column, now re-greased and repainted installed back into the cart
Front suspension before being put back on
Major drivetrain components like the battery, motor controller, and motor
New brake discs installed on the axles
New(much meatier) off-road tires from a John Deere Gator 4 by 4(old tires on the left)
Test wiring of the motor, battery, and motor controller setup on my workbench
Close-up of the rear axle with cleaned and repainted suspension
Wider shot of the cart from the rear
New motor mount installed
Cleaning up old gear to prep for modification
Lining up new and old gear to drill holes
(using stencil from before)
New gear and motor attached
Most recent photo of the cart. The new brake system is fully installed and the suspension is mostly restored. I am going to paint the front suspension arms soon.
Removing old axle gear to adapt it to a 78 tooth gear that I purchased separately
Marking up where holes need to be drilled for new gear to be seated
New gear attached and re-mounted to axle
