Electron car, front

The Car:

The chassis is made out of a combination of 25mm aluminium extrusions and 1.6mm aluminium plate, which has been bonded and riveted together. This structure is 100% recyclable. The main running gear has come from an old Go-Kart, this includes axles, bearings, steering components wheels & tyres, brakes and drivetrain. Polycarbonate which is also 100% recyclable has also been used for such things as the steering wheel. The body and paintwork has been supplied by Lotus, being of one of their old Soapboxes which have competed in the Goodwood downhill event. The seat belts and brake light have come off an old Lotus Formula 1 car. This part of the car has been designed and made by Robin Shute as part of his GCSE project.

frame and motor

Electron-Technical Specification

Chassis - Aluminium space frame made out of 25mm square extrusions, bonded and riveted using aluminium flitch plates

Body - Lotus 119A body made out of GRP. Body is in 4 parts, main body, seat rear cover and front clamshell

Motor - Fracmo 24v 240w dc electric motor limited to a maximum speed of 2000rpm.


Batteries - two Lucas type 096 12v batteries with a capacity of 75 Ah weighing approx 20kg (44lbs) each

Drivetrain - Power transmitted via a 219 grade Kart chain directly to the rear axle. Motor gear also has a one way roller bearing and fan to allow freewheeling and assist cooling

Suspension - no form of mechanical suspension, only flex in the chassis and tyres. Rear has a solid 25mm axle connected to the chassis via two bearings. To overcome the problem of no differential, one wheel is not directly connected to the axle, and so is allowed to freewheel in both directions.

steering wheel

Steering - Column, stub axles, king pins and track rods all off a kart, steering has Ackermann geometry around 70%. Stub axles connected to a 38mm hollow aluminium front axle, which is connected to the chassis via exhaust clamps and 2mm ally sheet. Steering wheel made out of 2 see-through polycarbonate butterfly shaped plates with the instruments positioned between the plates.

Wheels & Tyres: - Go kart type front wheels. Bearingless in the rear, Front wheels locate onto stub axles via bearings. Tyres are standard front Kart tyres slicks, rears being slightly larger in diameter to fine tune the gear ratio.

Brakes - Single mechanical calliper operating on the rear axle via a disc.

Weight - Approx 46kg (101 lbs) without batteries and driver

Dimensions - Length: 2m, Width 1.2m

Safety equipment - 4 point harness, and roll hoop made out of 38mm
Aluminium tubing.

Electrical specification - car is fused at 70amps. Power is transmitter via a Relay off a civil jet. There are three low tension circuits for the horn, relay and brake light.