Designed and built a lightweight electric kart chassis for endurance racing
Integrated protected electronics and organized wiring for reliability and safety
Developed a drivetrain and gearing system optimized for efficiency and steady speed
Focused on long runtime and predictable handling rather than maximum acceleration
Built the vehicle to meet competition safety and inspection requirements
Waterloo EV Challenge - Fall Race
Introduction
This project involved designing and building a lightweight electric kart for the Waterloo Electric Vehicle Challenge. The goal was to create a clean, drivable EV with efficient power use, safe electrical systems, and reliable performance over long race durations.
Date
October, 2025
ROLES
Builder
Designer
Functions
Fast Driving
Endurance Laps
What?
How?
Designed a lightweight but durable chassis structure for stability and reduced drag
Installed strain-relieved wiring and protected electrical components to prevent failures
Selected efficient motor gearing to balance speed, torque, and battery endurance
Tuned the vehicle for consistent speed and smooth handling on track
Conducted testing and adjustments to optimize reliability before racing
Results:
Successfully built a fully drivable electric kart meeting competition safety standards
Achieved stable handling and efficient power usage during testing
Demonstrated strong integration of mechanical design, electrical systems, and drivetrain tuning
Developed practical experience in EV design, wiring safety, and endurance optimization
OCTOBER 2025Oct · 2025
Waterloo EV Challenge — Build Timeline
1
Wood Prototype
Rapid mockup of wheelbase, steering angle, and pedal ergonomics. Validated brake feel before metal.
2
Final CAD
Full frame and drivetrain model. Set sprocket ratio and chain tensioner. Checked clearances and made cut drawings.
3
Electrical
Integrated MTX-35 battery and hub motor. Added 12→24 V and 24→48 V converters. Bench tested voltage, current, and polarity.
4
Aluminum Frame
Riveted and assembled box-tube chassis with gussets, integrating 3D-printed mounts and Lexan panels; battery box and controller installed with fuse.
5
Fall Race
70-minute endurance race; as driver I managed efficiency and pace, carrying speed on straights and choosing curve lines for the highest exit speed to pass.
Rapid mockup of wheelbase, steering angle, and pedal ergonomics. Validated brake feel before metal.
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