The car frame and sensitive body parts were made from.. wood. Yes, from wood. I used pine for the frame - it's ligth and flexible wood, good for such construction. More relevant parts like front suspension were made from oak which is hevier but also way stronger than the pine. If You are thinking that it is not good idea, bare in mind, that first cars were also made from wood. Anyway, after few months of driving my go cart by my son everything works perfectly fine.
I choose the 24V 350W DC electric engine. It's enough for my son. I projected the whole thing to run with top speed about 9MPH. Engine RPMs was reduced by built in gears/transmission to 600 RPM and then with two other gears from motorcycles. To power the rear wheel I've used free-wheel to avoid back currents (ie. when riding down the hill). Such back currents could broke the engine controller. Controller is some cheap chinese device,
I've used two 12V 18AH batteries. They last for 3-6hours of driving the car. Batteries are in the front of the car to balance the engine weight (which is on the rear).
If You have more questons - I will answear them.
Oh, important thing - the car is made mainly from wood and it's construction is very easy, so if You have time, workshop and kids - I recommend to build electric car for Your kids. It's not so hard and they will definitely have a real fun driving it.
Hera are some pictures from building process (with comments)Frame of the car. Made from pine wood (flexibility and low weight) and oak (strenght)Parts of the suspension. Made from acacia and bicycle headsets.Steering wheel is mounted on standard construction screw (used in house building)
Steering is available through the two wires.Before painting I need to remove any bumps and cover knotsAfter covering car body with first undercoat layer
So, what do You think ? If You have some question, need more instructions - write to me. I will answer.