Table of Contents

1.0
INTRODUCTION...................................................................................................3
1.1 Team
Details............................................................................................... ........3
1.2 Current
Scenario............................................................................................... ...6
1.3 Problem
statement................................................................................................6
1.4
Objectives............................................................................................................6

2.0 PROJECT
DESCRIPTION.......................................................................................7
2.1 The Project
Details..............................................................................................8
2.1.1 Basic Functions............................................................................................8

3.0 PROJECT
DESIGN...............................................................................................11
3.1 Concept
Design................................................................................................11
3.2 Material Selection (TRIZ
Method)....................................................................12
3.3 Benchmarking.................................................................................................13
3.4 Final Design (Material).....................................................................................15

4.0 BUSINESS AND MARKETING

PERSPECTIVES.................................................33
4.1 Introduction..33
 4.2 Initial Business
perspective...................................................................................33
4.2.1 Marketing Strategy33
4.2.2 Marketing Objectives33
4.2.3 SWOT
Analysis.34
4.3 Initial Market study /
survey..................................................................................34
4.3.1 Target Market34
4.3.2 Positioning.34
4.3.3 Strategies...35
4.3.4 Pricing...35
4.3.5 Place..36
4.3.6 Promotion..36
4.4 Marketing
Research.............................................................................................37
4.4.1 End-User Expectation..37
4.5 Notes of Meeting
(NOM).39
4.5.1 First Meeting39
4.5.2 Second
Meeting39
4.5.3 Third
Meeting...39

5.0 DESIGN
ANALYSIS.............................................................................................24
5.1 Material
Selection.............................................................................................24
5.2 Final Design
Analysis.......................................................................................24
5.2.1 Linear Static Analysis...25
 5.3 Collision
Analysis.29
5.3.1 Frontal
Collision....30
5.3.2 Rear Collision31
5.3.3 Side Collision32

6.0 PROJECT BUDGET40

6.1 Prototype
Budget...............................................................................................41
6.2 Project
Budget...................................................................................................41

7.0
CONCLUSION.....................................................................................................43
7.1
Summary...........................................................................................................43
7.2 Seek
Approval...................................................................................................43

8.0
REFERENCES.....................................................................................................44

9.0
APPENDICES......................................................................................................46
 CHAPTER 1
INTRODUCTION

1.1 Team Details

a) Team Name

Eco-Lancers.
Eco : Related with the environment.
Lancers : A military unit formerly composed of light cavalry armed with lances to
fight in wars.

b) Motivation Tagline

Technology you can enjoy

c) Official Logo
d) Team Members And Member Roles

Project Team Head : Nur Izzul Rafie bin Zahidin (50218114286)

Lead Secretary : Effa Riza binti Abdul Rait (50218114215)
Lead Designer : Saiful Omri bin Abd Hafidz (50218114050)
Assistant : Muhamad Amirul Asraf bin Abdullah (50213113133)

Lead Procurement : Hilmi bin Suliman (50218114153)

Assistant : Muhammad Syafiq bin Zulkifli (50218114216)

Lead Fabrication : Aliff Fitri bin Afandi (50218114048)

Lead Test & Commissioning : Muhamad Asyraf bin Mohd Bazari (50218114002)

Lead QA : Nur Azlinda Wati binti Sumardi (50218114182)

Lead Analysis : Mohamad Shahrul Nizam bin Harun (50213113157)

Lead Assembly : Shahrin bin Kamaruzaman (50218114021)

Assistant : Amierul Hazzazie bin Othman (50218114052)

Control System Team : Saiful Omri bin Abd Hafidz

: Muhamad Amirul Asraf bin Abdullah
: Muhammad Syafiq bin Zulkifli

Main Frame Team : Effa Riza binti Abdul Rait

: Nur Azlinda Wati binti Sumardi
: Nur Izzul Rafie bin Zahidin
: Mohamad Shahrul Nizam bin Harun

Power Train Team : Amierul Hazzazie bin Othman

: Muhamad Asyraf bin Mohd Bazari
: Shahrin bin Kamaruzaman
: Hilmi bin Suliman
: Aliff Fitri bin Afandi
 e) Team Organization Chart

Nur Izzul Rafie

bin Zahidin
Project Team
Effa Riza Head
binti Abdul
Rait
Lead
Secretary
Saiful Omri
bin Abd Shahrin bin
Hafidz Hilmi bin Mohamad Kamaruzaman
Lead Suliman Shahrul Nizam Lead Assembly
Designer Lead
Procurement
bin Harun
Muhamad Lead Analysis
Amirul Asraf Amierul
bin Abdullah Hazzazie bin
Muhammad
Assistant Othman
Designer Syafiq bin Assistant
Zulkifli Assembly
Assistant
Procurement Nur Azlinda
Wati binti
Sumardi
Lead QA

Aliff Fitri bin Muhamad

Afandi Asyraf bin
Lead
Fabrication Mohd Bazari
Lead Test &
Commissioning
1.2 Current Scenario

There are a lot of motor sports in the world including bikes and cars. The most famous
Formula Zero is one example of them. Basically, the motorsports are a competitive event
which involves motorized vehicles. Nowadays, motorsports are becoming more and more
popular in Malaysia. The competition becomes a platform for Malaysian to develop new
technologies and attract the attention of public from involving unhealthy activities (Mora,
Romero, & Ruperez, 2011).

In motorsports competition, the rules must be followed for the safety and fair game
(Mora, Romero, & Ruperez, 2011). It is very important to have a very safe track for the
competition to be conducted for audience. Two months ago, a Go-Kart Education Innovation
Motorsports and Automative Race (EIMARACE) 2016 has been held at Indera Mahkota
Sukpa Complex in Kuantan. During the go-kart race, a 131cc engine go-kart slipped off the
track and crashed through barriers before hitting the audience. A man and his young
daughter were killed, while his wife and son were injured along with several other people at
the event. From the accident, we learnt that the organizers must provide a safety environment
for the drivers and audiences before conducting the race.

Go-karting motor sport becomes one of the famous motorsports in Malaysia. Most of
the go kart in Malaysia uses petrol to move. This method does not consider eco-friendly. Go-
karting got the attention after the documentary, TV show and also write the papers about the
go-karting sport. This kind of exposure encourage more Malaysian to join and participate
with the sports. I am sure that this activity will become more popular in the future.

Energy development is a very important factor for success in industrialization and

important role for sustainable development of nation. Currently in Malaysia, hydrogen fuel
cells act as an alternative for green energy technology to reduce the problems on energy
sustainability and pollution due to fuel technology (Wan Mohamad, Atan, & Sin, 2009).
Research and developments work and continuous education has already implanted in
Malaysia for about 12 years (Wan Mohamad, Atan, & Sin, 2009) to gain more knowledge
and interest to fuel cell technology.
1.3 Problem Statement and Challenge

Nowadays, a lot of company were interested to do go kart business. This is due to the
increase of public interests towards go-karting motorsports. In order to have a large amount
of profit, they use low cost of materials for fabricating of the go kart. Hence, endurance type
of go kart is created. Subsequently, the customers are facing a disastrous situation without
knowing the capability of the go-kart is reduced. This further action will weaken the
condition of the go-kart.

With the increase of public interests towards go-karting motorsports, it will come a
problem to a group of people with low income to participate in this sport due to high cost.
The problems need to be overcome to give the opportunity to them to get involved. An
affordable go kart must be established so that all groups of people can get involved.

1.4 Objectives

1.4.1 The objectives of this project:

i. To reduce the usage of petrol as the main medium.

ii. To produce an eco-friendly go kart.
iii. To produce low cost go kart.

1.4.2 The improved objectives of the project

i. To compete in Go-Kart Event Display.
ii. To produce affordable go kart.
iii. To produce high endurance go kart.
iv. To implement all the knowledge gained during the development of this
project to apply in the future.
v. To apply all the mechanical engineering knowledge in the projects.
vi. To develop entrepreneurship skills.
 CHAPTER 2

2.0 PROJECT DESCRIPTION

The development in karting has expanded rapidly together with advanced technology. As this
motorsport become popular among citizens, those go-karts manufacture started to improve
more on research and development to improve the go-kart in terms of the chassis design,
speed, braking system and transmission system. Nowadays go-kart frames are made from
lighter iron or materials which is more durable and it can absorb more vibration even if it has
no suspension. Designers, engineers and others have involved directly towards new
achievement in developing and improve all aspects. Environmental friendly go-kart is
considered a new achievement, for example they start to use the hybrid technology on go-kart
development which uses two or more distinct power sources to move the vehicle. Moped (a
motorized pedal bike) is the most common of hybrid because it combines the power of
gasoline engine with the pedal power of its rider.

Madras Rubber Factory (MRF) and Indus motors are the major bodies in karts and they are
offering karts between 2 lakhs (RM15, 000.00) and 3 lakhs (RM22, 500.00). But to make go-
karts popular, the price must come down. For that, many people are trying to build one under
1 lakh and we had also take up the challenge and make our go-kart under 78 K (RM 4,
800.00). This is a dream come true which the go-kart just under Rs. 100000 (Ravikanth,
Nagaraja, Rajagopal, & Murthy, 2015). For Design 3 subject, each group was assigned a
Capstone Project which is designing and fabricating a go-kart that will through
commissioning within 13 weeks. Then, if we improve in term of designing a go-kart with low
cost but the specification still remains same with previous design which is their safety, long-
lasting, comfort (ergonomic term) will make the productivity of go-kart better. For the
prototype, we are using electric motor powered by batteries in order to make the go-kart
move and achieving the Eco-friendly term. In this chapter, we will explain what kind of
mechanical use we are applying into this product specifically.
2.1 The Project Details

Basic Functions

There are a few basic functions of the go-kart that we emphasize in design session to
overcome the challenges or problem statement.

A go-kart that can carry a weight up to 150kg.

A go-kart that use a battery as power source.

Go-kart with the lowest cost but high specifications.

Go-kart that can be drove by the beginner until expert driver.

To complete the go-kart race without any problem.

In a Go-Kart, there are mainly six parts:

Chassis:

The chassis is an extremely important element of the kart, as it must provide, via flex,
the equivalent of suspension to give good grip at the front. Karts have no suspension,
and are usually no bigger than is needed to mount a seat for the driver and a small
engine. Chassis construction is normally of a square tube construction, typically MS
with different grades. In this kart, we use AISI-1023 Carbon Steel tube with 1 or
25.4mm for outer diameter. The chassis support the power unit, power train, the
running system etc.

Engine:

An engine of a go-kart is usually a small two stroke about 80cc. In this kart, we use a
single-phase capacitor electric motor which produces about 2880 rpm powered by
batteries and controller. We try to develop a go-kart that not using petrol as fuel
consumption by change the power-train to electric motor.

Specification of the motor:

Power: 1.5 kW (2hp)

Voltage: 220

Current: 12A

Speed: 2880rpm

Steering system:

For our kart, rack and pinion is chosen as steering system which is simple mechanism.
A rack-and-pinion gear set is enclosed in a metal tube, with each end of the rack
protruding from the tube. A rod, called a tie rod, connects to each end of the rack.

The pinion gear is attached to the steering shaft. When you turn the steering wheel,
the gear spins, moving the rack. The tie rod at each end of the rack connects to the
steering arm on the spindle.
Transmission:

Transmission means the whole of the mechanism that transmits the power from the
engine crankshaft to the rear wheels. In our prototype kart, the power from the engine
is transmitted to the pulley using chain, i.e. this is chain drive. The driver sprocket has
9 teeth and driven sprocket has 45 teeth. Usually go-karts do not have a differential
and so we eliminate differential from our vehicle also. The go-kart has no clutch and
gears because this is electric motor. The power from the engine is transmitted to the
rear two wheels using chain drive. We use chain drive because it is capable of taking
shock loads.

Tyres:

For go-karts, wheels and tyres are much smaller than those are used on a normal car.
This type of tyres commonly used for go-kart due to the grip. It is also can withstand
the high temperature. In this prototype go-kart, we use 11 diameter for rear tyre and
10 for front tyre. The recommended tyres pressure for the go-kart is 18 psi.

Brakes:

Brakes are one of the most important control components of vehicle which required
stopping the vehicle within the smallest possible distance and this is done by
converting the kinetic energy of the vehicle into the heat energy which is dissipated.
In this prototype go-kart, disc brake is used as the brake system. The brake pads press
on the surface of disc to reduce the speed of the go-kart. The brake must be efficient
enough to reduce and stop the go-kart within a minimum distance in case of an
emergency. The brakes must have good anti fade characteristics, to provide the safety
measure for the safety of the driver.
Go - Kart Specifications

To design and fabricate go-kart which will be safe by ergonomically, economically

and by all means safety considerations following specifications were set during
designing:

a. Driver Ergonomics.

b. Serviceability and maintainability.

c. Design of flexible roll cage.

d. Use of optimum power efficiency.

e. Cost of the components.

 CHAPTER 3

3.0 PROJECT DESIGN

3.1 Concept Design

The main idea behind the Conceptual Design is to maximize the probability of the
final product. Hence, a conceptual design should be worked in sufficient detail to
allow estimates of cost, weight, overall dimensions and power consumption. During
this first phase of the design process, decisions should be made about major design
features such as primary sub-systems and major algorithms. The designer should also
present the rationale for making these decisions, supported by relevant experiments.
An arbitrary decision, especially early in the design process, means a wasted
opportunity for improving quality and reducing cost. By using a TRIZ or popular
method without questioning is in fact nothing but making an arbitrary decision.
During the conceptual design phase, one must question the accepted or
conventional ways of doing things and look for possible alternatives.

Broad solutions to the defined problem are developed often in the form of design
options. This phase places the greatest demand on the designer in terms of creative
thinking, since innovations can originate here. Design is not only about the final
product but also about the feasibility and cost-effectiveness of the manufacturing
process. When the designers choose a part shape, a circuit or an algorithm, they must
also think about how these will be manufactured or implemented. Is there an easier
way to achieve the same purpose with a different material, shape, circuit or
algorithm? should be a frequently recurring question in the designer's mind.

The feasibility of design decisions or their alternatives can only be validated if major
aspects of the design such as major sub-systems or algorithmic components are
verified through sub-system tests. Although it is not a guarantee, the positive results
of these preliminary tests convince the customer that the design has a high probability
of success upon integration and acts as an experimental Proof of Concept on a sub-
systems or module level.

3.1.1 Material Selection (TRIZ Method)

TRIZ methodology presents a systematic approach for understanding and defining

challenging problems, difficult problems require an inventive solution, and TRIZ
provides a range of strategies and tools for finding these inventive solutions. One of
the earliest findings of the massive research on which the theory is based is that the
vast majority of problems that require inventive solutions typically reflect a need to
overcome a dilemma or a trade-off between two contradictory elements. The central
purpose of TRIZ-based analysis is to systematically apply the strategies and tools to
find superior solutions that overcome the need for a compromise or trade-off between
the two elements.

The combination of all of these concepts together the analysis of the contradiction, the
pursuit of an ideal solution and the search for one or more of the principles which will
overcome the contradiction, are the key elements in a process which is designed to
help the inventor to engage in the process with purposefulness and focus.

The benefit of TRIZ is understanding that contradictions can be methodically solved

with application of innovative solutions. Three fundamental principles of TRIZ
conceived as follows:

a. Developed an ideal design.

b. Contradictions help to solve the problems.

c. Innovation process can be configured as systematic.

TRIZ includes analytical tools that are necessary for problem solving and it is also
knowledge-based tools that are necessary for system transformation and their
theoretical foundations. TRIZ uses algorithmic approaches for improving legacy
systems or designing new systems. Therefore, it includes to evaluate the available
data rather than estimation. The main goal of :

a. Contradictions
b. Perfection
c. Functionality
d. Use resources.

Using all the information about the problems of the products, the analytical tools of
TRIZ can be used for transforming, modelling and analysing problems. Also, it is a
special analytical tool that gathers substance-field analysis, conflict analysis, required
function analysis and other techniques.

3.1.2 Benchmarking

Benchmarking is comparing one's business processes and performance metrics to

industry bests and best practices from other companies. Dimensions typically
measured are quality, time and cost. In the process of best practice benchmarking,
management identifies the best firms in their industry, or in another industry where
similar processes exist, and compares the results and processes of those studied (the
"targets") to one's own results and processes. In this way, they learn how well the
targets perform and, more importantly, the business processes that explain why these
firms are successful.

Benchmarking is a way of discovering what is the best performance being achieved,

whether in a particular company, by a competitor or by an entirely different industry.
This information can then be used to identify gaps in an organizations processes in
order to achieve a competitive advantage. Thus, it is important for Six Sigma
practitioners to:

a. Understand fully the purpose and use of benchmarking.

b. Understand the difference between benchmarking and competitor research.

c. Gain insight to ensure that benchmarking is in alignment with the companys

management objectives.

Figure 3.1: Six Sigma Process

 Define Process

Data Collection

Data Comparison

Analysis

Action (Product Planning)

Figure 3.2: Benchmark Methodology

Table 3.1: Design benchmarking for all the purposed design and the final design selection.

Component/ Proposed Proposed Proposed Final Design

Design 1 Design 2 Design 3 Selection
Part

Frame AISI 4130 AISI 1023 ASTM A312 AISI 1023

Chrome-Alloy Stainless Steel Carbon Steel
Carbon Steel
(Chromalloy)
steel

Belt Integral Motor Belt

Spindle
Spindle Driven Driven

Hub Tool Steel Stainless Steel Mild Steel Mild Steel

Tyre 10 x 4.5 Beach 10 4.5 10 x 4.5 10 x 4.5

Buggy Rims Snowmobile Magnesium Magnesium
rims Rims Rims

Tie Rod Steel

Mounting Weld Nuts and Nuts and

Joint Bolts
Bolts

Steering Rod Tool Steel Stainless Steel Mild Steel Mild Steel

Steering Full Circle Half Circle Full Circle

Wheel

Polymer Carbon Fibre Carbon Fibre

Type Type
Seat Type Cushion

3 Point (Lap 3 Point 2 Point 2 point

and Shoulder) Retractable
 Seat Belt (Lap Only) (Lap Only)

Engine 2 Stroke Fuel 4 Stroke Fuel Electric Motor Electric

Engine Engine Motor
Type

Lithium Battery Lead-Acid Zinc Carbon Lithium

Battery Battery Battery
Battery

Brake Type Scrub Brake Band Brake Disc Brake Disc Brake

Clutch and Pulley and Pulley and

Belting Belting Belting
Transmission Gear

Ball Spherical Pillow Block Pillow Block

Bearing Bearing
Bearing Bearing l Bearing

Figure 3.3: Purposed design 1

Figure 3.4: Purposed design 2

Figure 3.5: Purposed design 3

 3.2 Final Design

Table 3.2: Final design materials selection.

No Component/Part Final Design

1 Frame AISI 1023 Carbon Steel

2 Spindle Belt Driven

3 Hub Mild Steel

4 Tyre 10 x 4.5 Magnesium Rims

5 Tie Rod Alloy steel

6 Mounting Joint Nuts and Bolts

7 Steering Rod Mild Steel

8 Steering Wheel Full Circle

9 Seat Carbon Fibre Type

10 Seat Belt 2 Point (Lap Only)

11 Engine Type Electric Motor

12 Battery Lithium Battery

13 Brake System Disc Brake

14 Transmission Pulley and Belting

15 Bearing Pillow Block Bearing

3.2.1 Compartment details:

1. Frame ( AISI 1023 Carbon Steel )

Many racing chassis manufacturers use

AISI 1023 (carbon steel) for
manufacturing their chassis. They,
however draw tubes at varying diameters
to accommodate bends. We will use this
material because it can easily get, cheap
and easy for mounting process.

2. Spindle

In the final design, we are using a spindle

for the turning radius of the tyre because
spindle is far cheaper on fabricate and
easier if than conventional steering
system and in go kart we not using
suspension system and is suitable to using
spindle.
3. Hub ( Mild Steel )

This external shaft locking device is a

reliable and durable component that
features high torque and impressive
concentricity. It is self-centering and the
axial hub position can be moved during
the clamping process.

4. Tyre ( 10 x 4.5 Magnesium Rims )

Magnesium alloys and magnesium

casting techniques have progressed
significantly in the last forty years. Real
Nostalgia magnesium wheels are vastly
superior to any of the old magnesium
wheels in terms of balance, consistency,
concentricity, corrosion resistance,
porosity, purity, sealing, and surface
finish.
5. Tie Rod ( Alloy steel )

Tie rods are commonly manufactured

using low carbon steel, but higher
strength assemblies can be
manufactured. Carbon or alloy steel tie
rod assemblies can be supplied either
plain finish or hot-dip galvanized, and
stainless steel tie rod assemblies are
common as well. Complete tie rod
packages are assembled in our facility to
ensure accurate thread fit before shipping
to mounting joint.

6. Mounting Joint ( Bolt and Nut )

In the final design, we using bolt and nut

as a joining because the bolts and nuts are
easier to fabricate and dismantle. We
using several sizes in the fabrication
process of the go-kart.
7. Seat ( Carbon Fibre Type )

In final design, we are using carbon fibre

seat because it is lighter then
convectional seat go kart. This seat is
quite expensive but in making of race go-
kart it is important to consider about the
weight because speed of go-kart would be
affected by the weight.

8. Seat Belt ( 2 Point Lap)

We are using two-point lap seat belt

because for this project, safety is one of
the important features of the go-kart. A
two-point lap seat belt is just enough to
ensure of the driver safety
9. Engine ( Electric Motor )

In final design, we are using a induction

single phase electric motor it is because
electric motor are more eco-friendly if
compare then two stroke and four stroke
engine. Then another conventional go-
kart also using electric motor but the
different between induction motor is it
more torque then the other electric motor.

10. Battery ( Lithium )

In final design, we are using a Lithium

Battery (LiPo) it is because induction
electric motor are using a AC current that
will converted into DC for using in go
kart so we choose to using LiPo battery
that had a Voltage more high then other
battery.
11. Brake system ( Disc Brake )

In final design, we are using a brake disc

system it is because brake disc are more
efficient then brake shoes in safety
aspect. Our go kart using only one brake
disc system at drive shaft it is because
only one disc it more enough to stop it.

12. Transmission ( Chain )

The clutch sprocket and the main drive

sprocket should be perfectly aligned so
they don't rub against the side links.
Rubbing wears the teeth down rapidly
and absorbs horsepower.

13. Bearing ( Pillow Block Bearing )

In final design, we are using a a pillow

block bearing for drive shaft bearing it is
because the pillow block are one of the
part that can connect movement part like
drive shaft then the pillow block more
easier to fabricate if compare to other.
3.2.2 Design Drawing

Below are the sketches and Computer Aided Drawings (CAD) of go-kart:

Figure 3.6: Side view sketch.

Figure 3.7: Plane view sketch.

Figure 3.8: Front view sketch.

Figure 3.9: 3D view sketch.
Figure 3.10: CAD side view.

Figure 3.11: CAD 3D view.

According to the result, we approached our design by considering all possible
alternatives for a system and modelling them in CAD software like SolidWorks and
subjected to analysis using HyperMesh software. Based on the analysis result, the
model was modified and retested and a final design was produced.

The design process of the vehicle is iterative and based on various engineering and
reverse engineering processes depending upon the availability, cost and other factors.
These are the design process objectives:

a. Safety

b. Serviceability

c. Strength

d. Ruggedness

e. Standardization

f. Cost

g. Driving feel and ergonomics

h. Aesthetics
3.2.3 Frame Design

The frame is designed to meet the technical requirements of the competition and the
objective of the chassis is to encapsulate all components of the go-kart, including a
driver, efficiency and safety. Principal aspects of the chassis focused on during the
design and implementation included driver safety, drive train integration, and
structural weight, and operator ergonomic. The number one priority in the chassis
design was for the driver safety. By the competition rules and Finite Element Analysis
(FEA), the design assured.

Figure 3.12: Final frame design.

The material AISI 1023 carbon steel is used because its relatively soft and strengthens
as well as good manufacturability. A good strength material is important in a roll cage
because the roll cage able to absorb as much energy as possible to prevent the roll
cage material from fracturing at the time of high impact. Carbon steel has chosen for
the chassis because it has structural properties that provide a low weight to strength
ratio.
3.3 Operation and Maintenance Manual

CONTENTS

1. Introduction

2. Technical details

3. Safety guidelines

4. Maintenance

4.1 Frame

4.2 Wheels and tyres

4.3 Steering system

4.3.1 Front alignment

4.4 Driving gear

4.4.1 Chain

4.5 Plastic parts

4.6 Lubrication

4.7 Maintenance and adjustment of the disc brakes

5. Safety

5.1 Wheel

6. Maintenance schedule

7. Warranty
1.0 Introduction

This operation manual contains important safety information and maintenance

information. All information, images and specifications contained in this manual are
based on the latest product information available at the time being. Most of the
maintenance work on the go-kart can be carried out by the owner.

2.0 Technical Details

Width: 1340 mm

Length: 1800 mm

Height: 830 mm

Empty weight: 32-60 kg

Carrying capacity: 90 kg

Tyre pressure (at 15C, front and rear) : 18 psi

3.0 Safety guidelines

a. Before using the go-kart, check if everything functions properly.

b. Adult supervision for children under the age of 15 years old.

c. This go-kart is not allowed on public roads. Always drive it at appropriate

speed, depending on the situation. Driving down a slope slantwise, the go-kart
may overturn. Downhill drive with a considerable speed, resulting in a longer
break path. Sharp bends at high speed also may cause the go-kart to overturn.

d. Always pay attention to the environment and surroundings during the go-kart
run.
e. Do not drive under the influence of alcohol or drugs which have a negative
effect on your perception or reaction.

f. Do not place unnecessary objects on or beside the clutch handle or the wheel.
Make sure the brake and pedal are functioning.

g. Clothes and limbs may get stuck in revolving or hinged parts. Avoid wearing
loose attire such as scarves or shoe laces. It can cause accidents.

h. Avoid contact with the wheels when driving the go-kart.

i. The brochure contains guidelines on age categories. The owner/driver is

responsible for deciding whether this go-kart is age appropriate.

j. Make sure that for every drive the driver's seat is in the right position with
regard to the pedals to allow for safe driving.

k. Do not get on or off while driving.

l. Do not overload the vehicle.

m. Do not drive in the dark without lights.

n. Protective covers having been removed for maintenance purposes should

always be put back in the original state before use.

o. When parking the vehicle, always put it in brake with the lock brake.
4.0 Maintenance

4.1 Frame

The frame is powder coated. This creates a hard coating. To prevent from corrosion, it
is important to regularly clean the frame. Grease the frame for the purpose of
conservation, only use acid-free vaseline. Minor damage may be restored with some
paint. The right varnish may be obtained from your dealer.

4.2 Wheels / Tyres

Wheels may have either needle bearings (Figure 4.1) or ball bearings (Figure 4.2).
Needle bearings should be cleaned and lubricated annually to ensure the wheels run
smoothly. Regularly check the wheel rims and tyres for damage (cuts, tears, bumps)
Attention: damage to rims and tyres may cause accidents.

Figure 4.1 Figure 4.2

Tyre pressure should be 1 bar at least and 1.5 bar max. (Remember pressure increases
at high temperatures). At the right pressure, the go-kart runs smoothly and lightly. If
there is not enough pressure the tyres tend to get punctured more easily and excessive
wear and tear occurs. If there is too much pressure the tyre can come loose. This may
lead to dangerous situations. (Be aware that pressure increases under high
temperatures and in blazing sun!) Tyres should not get into contact with oil, grease or
fuel. Make sure the valve caps are always on.
4.3 Steering system

Steering system should be regularly greased for it to run smoothly. For the adjustable
wheel, it is important that the identifying mark on the side of the inner control tube is
not visible. If it is visible, the inner control tube should be pushed back. Steering
system of the go-kart needs to be checked monthly for the following:

a. Breaking and/or damage of all parts of the steerage

b. Controls (lubricate all rotation points)
c. Alignment front wheels (see pictures next page) for models with double ball
steerage - stuck bolts

4.3.1 Front alignment for models with double ball steering system

a. Check if bottom of strip is in upright position. The correct position is

shown in Figure 4.3.

Figure 4.3

b. Then check the smallest deflection of the left and right wheel with the
front bumper (As indicated in Figure 4.4 and Figure 4.5 at the bottom of
the page).
 Figure 4.4 Figure 4.5

c. Loosen the steering swivel at the side of the wheel with the smallest
deflection. In Figure 4.6 and 4.7, the left wheel can be calibrated (by
using 13 and 19 spanner). Then push against the wheel in the direction
away from the bumper. After that, tighten the steering swivel well.

Figure 4.6 Figure 4.7

4.4 Driving Gear

4.4.1 Chain

The chain needs to be greased regularly in order to have it run smoothly. It

should only be possible to push in the chain 2 to 3 cm in the middle. Make
sure the rear axle does not move when the chain is pushed in in the middle. If
the chain is pulled too tight, the go-kart will peddle heavily and the axle could
break. If the chain is not tight enough, the chain guard may be damaged.

The back chain is tightened based on Figure 4.8 and 4.9:

 Remove the protective plate from the back hood. Make sure the hub remains
exactly parallel to the rear axle (maximum 1 mm difference in distance
between rear axle and the small axle of the brake hub left and right), as can be
seen in the picture below. It should be possible to push in the chain in the
middle with the thumb for about 3-4 mm.

Figure 4.8 Figure 4.9

4.5 Plastic Parts

The plastic parts will have to be checked regularly for damage and breaking. If
breaking occurs, the specific part should be replaced immediately by an original part
in order to guarantee the safety of the user.

4.6 Lubrication

Some Berg go-carts are equipped with grease nipples on the stub axle bushes. It is
recommended to grease the stub axles 1 to 2 times per year.

4.7 Maintenance and Adjustment for Disc Brake

If the brake system started to loosen grip, it needs to be squeezed furthermore. In
order to operate properly, you need to adjust the brakes. The cable connector where
the brake cables are connected is equipped with adjusting screws. By turning the
adjusting screws counter clockwise, the free movement of the brake handle decreases
and the disc brakes will perform better.

If the brake disc laterals runout, you need to adjust the brake calliper. By turning the
adjusting screw (Figure 4.10), you can move the brake calliper sideward.

Figure 4.10

5.0 Safety

This go-kart is produce for circuit use only. Each year an independent institution
checks if the products meet the required standards. This go-kart is a part of the
automotive product group. This means that the go-karts are not allowed on public
roads. Children (under the age of 15) should drive the go-kart under adult supervision.

5.1 Wheel

Check before driving, if there are any defects on the controls or whether the steering
system is smooth. If this is not the case, you need to solve this first. For instructions,
see under maintenance.
 6.0 Maintenance Schedule

Description Daily Every Every 6 Every Year

Month Month

Frame

Clean and check all
the nuts and bolts

Tyres

Check for damages
and tyre pressure

Steering system

Check for
damage/wear lubricate

Driving Gear

Check chain for
tightness

Plastic Part

Clean and check for
damages

Hubs

Clean and check for
wear

Stub Axle Bushes

Lubricate by means of
grease nipples
7.0 Warranty

a. The owner of this go kart product has the following warranty conditions on this
product.

Frame: 5 years after date of purchase.

All other parts: 2 years after date of purchase.

Parts subject to wear and tear (such as chain and tyres): no warranty.

b. The warranty only covers material or construction defects with regard to this
product or parts of the product.

c. The warranty expires in the following situations:

Incorrect and/or careless use of this product and use not according to the
intended purpose.

The product was not assembled and serviced according to the construction
manual.

Technical repairs to the product have not been carried out professionally.

Parts mounted afterwards do not meet technical specifications of the product

involved or have not been mounted correctly.

Defects as a result of climatological factors, such as corrosion or normal

ageing of the varnish.

The product is in use as a rental or is in another way available to several

persons unspecified.
e. This go kart is explicitly not liable for damage to (parts of) the product as a
result of:

Incorrect tune-up of driving mechanism, incorrect tyre pressure, incorrect

adjustment of wheel, chain and hubs.

Parts, such as chain and tyres, not replaced in time.

f. In the warranty period, all material or construction defects as determined will

either be repaired or replaced.

g. The owner of this product can only make a warranty claim by offering the
product for inspection to our dealer. The original warranty certificate (with dealer
stamp and fully completed) should be presented to the dealer at the same time, and
with original bill of purchase. If the owner has moved or the dealer is no longer
available under the name of eco-lancer.

h. If the warranty has not been presented, the owner will take care of all costs.

i. The warranty certificate is not transferable to other persons

 CHAPTER 4

4.0 BUSINESS & MARKETING PERSPECTIVES

Every successful business must have a business plan. This plan spells out among
others the ways the company intends to rationalize its resources, engage in production and
even handle its clients. Most importantly, a sound business plan must also include a
strategic marketing plan.

Strategic marketing planning is considered as a creative process in its right. Here, the
management and operations teams strive to come up with and implement practical marketing
strategies that can guarantee a stable flow of business for the company.

It should outline the current position of the firm regarding financial results. Such
analysis allows the planning team to identify the strategies that were previously put in place
and assess the success of the overall plan against the financial results. In the end, a SWOT
analysis reveals the current situation of the company. The following marketing plan had been
developed by Team 6, Eco-Lancers to obtain RM3600 in capital for the marketing of
Go-Kart and sell it for RM6500.

4.1 INITIAL BUSINESS PERSPECTIVE

4.1.1 Marketing Strategy

Eco-Lancers Go-Kart mission is to provide the customers with racing

experiences. The Go-Kart is endurance and eco-friendly product.

4.1.2 Marketing Objectives

Development of endurance Go-Kart to meet customer needs. Eco-Lancers

Go-Kart mission is to provide the customers with racing experiences. The Go-
Kart is endurance and eco-friendly product.
4.1.3 SWOT Analysis

a. Strengths :

Endurance Go-Kart
Eco-Friendly
Creative, yet practical designers from expert designer.
Price is cheaper than existed Go-Kart.

b. Weakness :

The capital necessary to grow the business

The difficult of developing brand awareness as a start-up business.

c. Opportunity :

Product development.

d. Threat :

Potential competition from already established market participation.

4.2 INITIAL MARKET STUDY

4.2.1 Target Market

Based on research, the data gathered through primary research and studying the
current scenario, the two primary markets will be targeted to several secondary
markets to help boost revenue. As the trend in industry is the majority of the sales
come from special events. The second primary market to be targeted, walk in racers
consists of member such as local people, tourist, trade show or convention attendants.
Walk in customer represented a wide array of ages and demographic. Therefore, in this
marketing plan we will address the interests of board category of people.

4.2.2 Positioning

Eco - Lancer will position itself as the premier carting company. This positioning will
be achieved by leveraging Eco - Lancer competitive edge in industry experience and
passion. We are confidence that new facility will be prosperous and become the
premier carting centre in the state. The company will look to acquire a share of the
existing market as well as increase market size by offering unique programs to new
age groups.

4.2.3 Strategies

The objectives are to position Eco - Lancer as the premier carting company. The
marketing strategy will seek to first create customers awareness concerting the offered
products and services and then develop the customer base. The main strength is to
give customers the go-kart experience that will lie in the highly differentiated
approach of the facility. The experience will offer entertainment for the whole family
by offering racing camps for children which will lead to interest form parents and
their participants in the sports. The facility will encourage its customers to gain an
interest in other motor sport, and will allow them convenient shopping for apparel of
their favourite drivers in the retail shop.
 The other marketing approach will be advertising in numerous industry magazines.
The automobile industry is supported by several different glossy magazines designed
to promote the industry as a whole. We are also confident that our carting with the
Eco - Lancer experience will appeal to the local people and visiting tourists and will
capture a significant portion of the current markets well as increase the market size.
We are determined to make Eco - Lancer Malaysias premiere facility for karting.

4.2.4 Pricing

Eco-Lancer provides a high quality that is customized to its clients needs. The price
of Eco -Lancer Go-kart based on two pricing strategy:

a. Cost Based Pricing

It is decide that the price per unit of Eco-Lancer go-kart estimated is RM 3000.
Based on, our survey result the respondents want the lowest price for go-kart. In
figure 4.1 a result of our survey.

Figure 4.1: The voted of respondents for the range of go-kart price.

b. Value based pricing

The price our group offered is relevant to the product designation and operation
system used. The product is considered as a custom made product as it is designed
 according to the problems faced by the go-kart researchers during the process of Eco-
Lancer Go-kart. Customer may find that this product price is fair after taking count the
product advantages and how it easy to drive.

4.2.5 Place

We use direct channel marketing as we go directly to the any go-kart centre in Malaysia
to place our product. Our product distributed by our agents and salesmen that will
approach the customers in the go-kart companies. Besides, the customers can directly
come to the company to discuss about the go-kart and buy it.

4.2.6 Promotion

We planned to promote our go-kart to all go-kart centres and track to play go-kart in
Malaysia. Besides that, we also promote to media social, newspaper and magazine as
short term to promote our go-kart.

4.3 MARKET RESEARCH

A lot of research was done such as a questionnaire, journals, visit go-kart manufacture and
saw the experience person in the manufacturing go-kart. Besides that, we has distribute 30
pieces of questionnaire for make our go-kart more interesting and suitable for our customers.
In additional, we visits to Dream Edge Innovation and Technology Centre in Bukit Jalil to see
how to start the proper work are conduct by Mr. Mohd Noor Bin Yahya before we proceed
our progress because we want to reduce our time and cost.

4.3.1 End - User Expectation

The end user expectations are recorded in Figure 4.2. Majority of the respondents are
expecting the transmission of go-kart are turn to automatic. Before this has many go-
 karts are manual transmission. This are difficult the driver to drive this go-kart to
using clash pedal. About 18 respondents want automatic transmission go - kart.

Figure 4.2: The results survey for type of transmission.

Besides that, respondents also make a choose type of materials. There are many type of
material to use for the frame of go-kart. But the famous material uses for Go-Kart are
steel, iron, mild steel and carbon steel. Our team has decide to use carbon steel as the
material for frame. Most respondents choose carbon steel is use as material frame for our
go-kart. It is easier for us to decide to buy the frame material. The Figure 4.3 show the
result of type of material is use in our frame.

Figure 4.3: The respondents results type of material.

 Our focus also at the steering system is use for our go-kart. There a few type for
steering system such as recirculating bold and nuts, rack and pinion and worm and roller.
For steering system our team member decide to use result of respondents to use in our
go-kart. From Figure 4.4 the most voted is rack and pinion so we use the rack and pinion
as our steering system.

Figure 4.4: The voted of respondents for type of steering system.

 4.4 NOTES OF MEETING (NOM)

Taking Minutes forms an essential part of most meetings. Their purpose is firstly to record
Action Points, i.e., what actions have been decided upon, who is responsible and what the
milestones and deadlines are. Secondly they record summaries of the discussions held at the
meeting.

Minutes are required in order to confirm any decisions made, record any agreed actions to be
taken, record which team member has been allocated any tasks or responsibilities and serve
as a record of the meeting's procedure and outcome.

Below are the Notes of Meeting of Eco-Lancers Team:

4.4.1 First Meeting

Refer Appendix 4.1

4.4.2 Second Meeting

Refer Appendix 4.2

4.4.3 Third Meeting

Refer Appendix 4.3

4.4.4 Forth Meeting

Refer Appendix 4.4

 CHAPTER 5

DESIGN ANALYSIS

5.1 Material Selection

Properties 1023 Carbon Steel

Cast Carbon Steel Low carbon steel
Sheet
Density (kg/m3) 7800 7858 7800
Youngs Modulus 200000 205000 210000
(Gpa)
Yield Strength 248.17 282.69 220.59
(N/mm2)
Tensile Strength 482.55 425 399.83
Poissons Ratio 0.32 0.29 0.28

Table 5.0: material selection

In material selection session, Eco-Lancers has selected three type of carbon steel which have
a difference properties.

5.2 Final Design Analysis

The next stage of design process is to analyze the final design. Analysis Department runs an
analysis for the three materials that has selected. FEA (Finite Element Analysis) will be
applied on each of material with the same design to make sure the proposed material is strong
enough to withstand the load from the driver and engine. First of all, each one of material will
undergo static loading to calculate the Factor of Safety.
 Figure 5.1: Frame analysis

5.2.1 Linear Static Analysis

a. Cast Carbon Steel

Table 5.1 : cast carbon steel table

Cast Carbon Steel

Type Minimum Maximum

Von Misses Stress (N/mm2) 1.70e+005 2.25e+002

Resultant Displacement (mm) 7.76e-002 1.47e-004

Yield Strength (Mpa) 248.17

Factor of Safety (FOS) 1.10

Displacement

Figure 5.2: Cast carbon steel displacement

Von Misses Stress

Figure 5.3: Cast carbon steel stress

c. 1023 Carbon Steel Sheet

Table 5.2 : 1023 carbon steel sheet

1023 Carbon Steel Sheet

Type Minimum Maximum

Von Mises Stress (N/mm2) 1.72e-005 2.40e+002

Resultant Displacement (mm) 1.90e-004 8.05e-002

Yield Strength (N/mm2) 282.69

Factor of Safety (FOS) 1.17

Displacement

Figure 5.4: 1023 carbon steel diplacement

 Von Misses Stress

Figure 5.5: 1023 carbon steel stress

d. Low Carbon Steel

Table 5.3: Low carbon steel table

Low Carbon Steel

Type Minimum Maximum

Von Mises Stress (N/mm2) 1.75e-005 2.44e+002

Resultant Displacement (mm) 1.21e-004 7.98e-002

Yield Strength (N/mm2) 220.59

Factor of Safety (FOS) 0.90

Displacement

Figure 5.6: Low carbon steel displacement

Von Misses Stress

Figure 5.7: Low carbon steel stress

 FEA of three different analyses Carbon Steel showed different stress and
displacement results. Hence 1023 Carbon Steel Sheet was selected because it has greater
safety factor than other two materials.

5.3 Collision Analysis

Design analysis proceeds with the collision analysis of the selected material. We
estimate the directions of impact force are from the front, rear and side. Based on (Yadav, et
al. 2014), they said that the impact time lies in between 200 ms to 1000 ms. So the impact
force estimation is 200 ms. We estimate our go kart mass is 200 kg including the driver and
maximum velocity can be up to 50 km/hr. We estimated force impact will be 10000 N we
assume that the go kart runs to the fixed object as the worst case collision.

5.2.1 Frontal Collision

Displacement

Figure 5.8: Frontal collision displacement.

Von Misses Stress

Figure 5.9: Frontal collision stress.

5.3.2 Rear Collision

In rear collision, the go-kart is assumed to be stationary, fixed and another go-kart
with same mass and velocity is 50km/hr collides with the design go kart.

Displacement

Figure 5.10: Rear collision displacement.

Von Misses Stress

Figure 5.11: Rear collision stress

5.2.2 Side Collision

As a side impact is most likely to occur, with the go kart hit by another go-kart, it was
assumed that neither go kart would be a fixed and stationary object. In side collision,
we assume the mass of the other go kart that is same with design go kart while the
velocity is 50km/hr.

Displacement

Figure 5.12: Side collision displacement

Von Misses Stress

Figure 5.13: Side collision stress

 CHAPTER 6

1.0 PROJECT BUDGET

6.1 Prototype Budget

Table 6.1: Prototype budget for the go kart are listed below.

N Quantit Material RM/Un Amou

Particulars Size (mm) Vendor
o y s it nt
RM
Axle and Aman
1 1 Steel 25.4
axle mount Speedwork 300.00 300.00
195.8x131.5x1 Aman
2 Battery 2 Lithium
75 Speedwork 250.00 500.00
Bearing, Ren Hup
Stainless
3 bush, nut and 14 M8 Motors
steel 9.54 133.55
oil Sdn. Bhd.
Nam Swee
4 Bearings 6 Cast iron 25.4 Bee Sdn.
7.25 43.50
Bhd.
Tujusama
5 Bolt and nut 2 Mild steel 8x45 Hardware
1.00 2.00
Sdn. Bhd.
Bolts, lock Advance
6 nuts, flat 17 Mild steel M8 Bolts Sdn.
0.11 1.80
washer Bhd.
Stainless Sri Kajang
7 Bush 2 38.1
steel Motors 80.00 160.00
Popular
Electrical
Diamond
8 Disc cutter 1 125x1.2x22.2 &
blade 5.00 5.00
Hardware
Trading
Purple
Documentati
9 1 - - Print Sdn.
on 23.50 23.50
Bhd.
Megohms
Electrical
10 3 Copper 2.32 Electronic
wire 2.10 6.30
Sdn. Bhd.
Aman
11 Fibre Seat 1 Fibre -
Speedwork 200.00 200.00
12 Go kart - - - Bengkel
 delivery & Besi Malik 300.00 300.00
labour cost
Speed
Steering
Aluminiu Karting
13 system and 5 M8x550
m Circuit 113.00 565.00
parts
Sdn. Bhd.
Aman
14 Hub 4 Mild steel
Speedwork 80.00 320.00
Nut, bolt, Woh Cun
15 2 Mild steel M12
and washer Sdn. Bhd. 5.23 10.45
Leong
Seng Auto
16 Pulley 1 Cast iron 114.3
[Link] 17.20 17.20
d.
G.G.M.
17 Spray paint 1 - - Hardware
7.95 7.95
Sdn. Bhd.
Thong Hin
Loong
18 Spray paint 5 - -
Hardware 9.20 46.00
Sdn. Bhd.
Sprocket and 101.6 mm & Aman
19 1 Steel
chain ANSI 35 Speedwork 90.00 90.00
Carbon Aman
20 Steel tube 6 31.75
steel Speedwork 60.00 360.00
Steering Aman
21 1 Steel 165.1
wheel Speedwork 50.00 50.00
Standwell
Aluminiu
22 Switch 1 10.16x20.01 Trading
m 5.10 5.10
Sdn. Bhd.
Speed
Aluminiu Karting
23 Tie rod 2 25
m Circuit 19.00 38.00
Sdn. Bhd.
Tyres and Aluminiu Aman
24 4 279.4
rims m Speedwork 100.00 400.00
Wrapper for NSK Trade
25 4 Plastic Std
paint job City 2.70 10.80
3,596.1
TOTAL
5
6.2 Project Budget Details for Mass Production.

Table 6.2: Details of variable cost for the go kart.

SALES RM
Sales price per unit 6,500.00
Sales volume per period (Units) 350.00
Total Sales 2,275,000.00

VARIABLE COSTS
Commission per unit 500.00
Direct material per unit 3,596.15
Shipping per unit 150.00
Supplies per unit 50.00
Other variable costs per unit 30.00
Variable costs per unit 4,326.15
Total Variable Costs 1,514,152.50

Unit contributing margin 2,173.85

Gross Margin 760,847.50

FIXED COSTS PER PERIOD

Administrative costs 349,800.00
Insurance 10,000.00
Property tax 7,500.00
Rent 60,000.00
Other fixed costs 60,000.00
Total Fixed Costs per period 487,300.00

Net Profit (Loss) 273,547.50

 Table 6.3: Table 6.3 Details of Cost Per Unit (CPU) production for go kart.

Percentage
Calculation
Item Basis Rate (e.g.) Calculation MYR/pc of
Basis
Quotation
3 days x
Design Hrs MYR 20/hr RM20 x 8 480 1.371 0.0%
hrs/day
Raw
material, As As
Sheet metal Kg manufacturer manufacturer
429.700 429.700 6.6%
weighs 15 list list
g/pc
As As
Std. part L/s manufacturer manufacturer 12.9%
837.200 837.200
list list
5 days x
MYR 5 to
Machining Hrs RM22.5 x 900.000 900.000 13.8%
MYR 60/hr
8hrs/day
Heat
Kg MYR 5/kg NA 0.0%
treatment
Tooling,
Piece
Stamping
(life MYR/piece NA NA NA NA
die at
span)
MYR15,000
Part MYR
Production, MYR 14.40/hr /
RM/hr NA NA NA
Stamping 14.40/hr 4500
Machine stroke/hr
MYR
Km, 0.8/km x
Handling & MYR 0.8 to
weight, 100km / 944.500 944.500 14.5%
Delivery RM60/km
volume 1,000 pcs
per delivery
5 days x
Admin & MYR 12.16 /
Hrs MYR 12.16 / 486.400 486.400 7.5%
Overhead hr
hr x 8hrs/day
Total - 3,599.171 55.2%
Profit
% 10 to 200 81.0% 2,915.329 44.8%
margin
Quotation
6,514.500 100.0%
to customer
 CHAPTER 7

CONCLUSION

7.1 IMPROVEMENTS

7.2.1 Project description

For our previous prototype, we proposed to use an electric motor powered by batteries in
order to make the go-kart move and achieving the Eco-friendly terms and conditions. With
the help of Mr Malik Bin Mat Desa, owner of Malik Bengkel Besi in Melaka as our hired
fabricator for the go-kart are willing to support this kind of project based on the experienced
in custom fabrication field. In terms of source energy for the go-kart, he recommended that
the Eco-Lancers Team divert from an electric go-kart to a hybrid go-kart. The suggestion was
made up due to the time challenge race that requires high powered engine to obtain the
average speed of a go-kart. Furthermore, they were willing to lend a petrol engine in order to
make the hybrid go-kart possible.

Engine:

For Eco-friendly go kart we used a hybrid engine. Hybrid engine use both a conventional
gasoline engine and an electric motor. They are far less polluting than gasoline-only vehicles,
making a big impact, as every unused gallon of gas saves up to 19 pounds of carbon dioxide
emissions. This can really add up nation or worldwide (Nolan, 2008-2011).

2 Stroke motor engine:

A two-stroke, or two-cycle, engine is a type of internal combustion engine which completes a

power cycle with two strokes (up and down movements) of the piston during only one
crankshaft revolution. This is in contrast to a "four-stroke engine", which requires four
strokes of the piston to complete a power cycle. In a two-stroke engine, the end of the
combustion stroke and the beginning of the compression stroke happen simultaneously, with
the intake and exhaust (or scavenging) functions occurring at the same time. Two-stroke
engines have a greatly reduced number of moving parts, and so can be more compact and
significantly lighter. We use SUZUKI RGV 120cc two stroke engines with electric motor to
combine a hybrid engine as the input power of go-kart.

Specification of two stroke motor:

Type: 2-stroke, air cooled

Valve system: "Reed" valve

Total cylinder: 1

Bore & stroke: 56.0 mm x 49.0 mm

Compression Ratio:7 .0:1

Carburettor: MIKUNI VM 20 SS, single

Starting System: Kick

Lubricant System: SUZUKI "CCI"

7.2.2 Project design

This project deals with design, fabrication and modification of go kart, which can be used in
customized go kart racing championships. The main objective is to build a high quality
competitive go-kart that can outperform the competition in acceleration, braking, and
manoeuvrability; as well as provide excellent driver ergonomics and vehicle aesthetics. The
fundamental intent of this project is to implement three years of theoretical engineering,
specifically theoretical knowledge into real-life practical applications that can ultimately be
used to develop real-world problem solving skills.

Engines by their nature are pumps, glorified piston pumps and they inhale and exhale gas. In
order to make a pump work better we need to increase its frictional capability (in other words
decrease its amount of friction), decrease its rotating mass, and also increase its pumping
efficiency. By adding a petrol engine in the go kart, we can consider the go-kart is a hybrid
go-kart.
7.2.3 Engine Maintenance Manual

i. Verify the engine nacelle is clean and free of fuel leaks, oil leaks, dirt and debris.

ii. Inspect all fuel and oil lines for signs of chafing

iii. Inspect the oil cooler and oil filter for signs of leaks and physical discrepancies.

iv. Check the following on the engine for cracks, dents, pitting or physical damage:

External cylinder barrels

Cylinder barrel fins
Areas between and adjacent to the cylinder barrel fins.
External surfaces of the cylinder head, including areas around
Cylinder head fins
Top and bottom spark plug bosses
Fuel nozzle bosses
Crankcase external surfaces
Accessories
Support structures adjacent to accessories

NOTE: If cylinder discrepancies are discovered during the visual inspection, perform the
Cylinder Inspections.

v. Check security of engine and accessory wiring harnesses, including ignition

leads. Check for signs of thermal breakdown, chafing, deterioration or improper
routing.

vi. Replace broken or damaged cushion clamps and stressed or broken wire ties.

vii. Check magnetos for external damage, cracks and mounting security. Ensure the
harness outlet plate is securely fastened to the magneto and the harness is
properly routed.
viii. Inspect external drive belts for nicks, cracks and visible wear; replace belts
exhibiting nicks, cracks, or visible wear. Check belt tension and adjust.

ix. Inspect the exposed area of the crankshaft between the crankshaft nose oil seal
and the propeller flange for evidence of corrosion.

x. Check electrical connectors for signs of corrosion or contamination; if external

corrosion or contamination is discovered, disconnect the connectors and inspect
the internal pins for corrosion or contamination.

xi. Inspect installed accessories for proper mounting and security. Inspect alternator
brush holders for soot accumulation. If large amount of soot is present, inspect
brushes.

NOTE: For items (xii xv), inspect for obvious signs of physical damage, wear or
deterioration, lose or missing hardware, leaks or foreign material that may hinder normal
operation. Correct any discrepancies.

xii. Inspect the physical integrity of the fuel system.

xiii. Inspect the physical integrity of the induction system air box, ducts, seals and
gaskets according to the air frame manufacturers instructions.

xiv. Inspect the physical integrity of the lubrication system

xv. Inspect the physical integrity of the exhaust system according to the air frame
manufacturers instructions.

xvi. Repair any observable damage or deficiency before the aircraft is returned to
service.
7.2 SUMMARY

This project will offer the client the enjoyment of a motorized vehicle. From
what we can conclude for this go-kart is that it is a 120cc, 2 strokes, 4 wheels and a
hybrid engine. The go-kart was designed using basic automobile principles. We use
1023 carbon steel as a frame of the go-kart. It is analysed using finite element
techniques to prove its effectiveness which is by using HyperMesh software. Static
analysis using finite element method was successfully carried out to determine
maximum deflection, stress and its location on chassis structure. The results of
analysis revealed that the location of maximum deflection and stress agrees well with
theoretical maximum location of simple beam. For the engine, this go-kart use an
internal combustion engine with petrol as a medium for combustion. For Eco-friendly,
we improved our go-kart by adding an electric engine and make it as hybrid engine.
Hybrid engine use both a conventional petrol engine and an electric one. They are far
less polluting than petrol only vehicles. Finally, we manage to build a low cost go-kart
within our budget of RM3600. According to the market price many people are trying
to build one under 1 lakh and we had also take up the challenge and make our under
78 K (RM 4, 800.00). This is a dream come true which the go-kart just under Rs.
100000 (Ravikanth, Nagaraja, Rajagopal, & Murthy, 2015). From this observation,
we can sell our go-kart around RM6500 and that would be around 81% for our profit
margin.

From what we can expect from this go kart, it has a great sustainability and
safe to be use. By applying the knowledge of mechanical engineering in the project,
during the development of this project we gain some extra knowledge and able to
implement it on our upcoming project. There were many challenges throughout the
development process. To come up with an excellent go-kart, the subsystems were
designed in such a way that they can achieve maximum performance. Finally, an
effective design for the go-kart was developed which is, our objective and basic
functions were achieved.
8.0 REFERENCES
1. Mehta, P. A., Padhiar, N., & Mendapara, J. (2011). DESIGN AND ANALYSIS OF
HYBRID GO-KART. International Journal of Advanced Engineering Technology,
2(1), 277-288.

2. Ravikanth, D., Nagaraja, C., Rajagopal, K., & Murthy, V. (2015). Fabrication of a
Model Go-Kart (With Low Cost). IOSR Journal of Mechanical and Civil Engineering
(IOSR-JMCE), 24-30.

3. Kanawade, N., & Siras, P. (2016). A LITERATURE REVIEW ON EXHAUST

MANIFOLD DESIGN. International Journal of Scientific Research Engineering &
Technology, 5(5), 286-289.

4. S. Rajadurai., & M. Afnas. (2014). Material for automotive exhaust

system. International Journal of Recent Development in Engineering and
Technology, 2(3), 82-89.

5. Patel, S., Patel, M., Patel, A., & Sanghani, C. (2015, February). Power Magnification
By Chain Drive. IJIRST-International Journal for Innovative Research in Science &
Technology,Volume 1 (Issue 9), pp.1-3

6. Veerapathiran, G., Dhanapal, P., Koumaravel, R., Narayanamoorthy, P., Ravi, V.,
&chandran.(2015,March). Power Transmission Through Timing BElt In Two
Wheeler [Link]. Journal of Engineering Research and Applications, Vol. 5 (issue
3),pp.20-25

7. Chow, H. Y. (2001). Go Kart's Design and Construction Based on Theoretical and

Experimental Findings. 61.

8. Gikuni Grace Waithira, K. H. (2014). HANDMADE ELECTRIC VEHICLE. This

Project Report Is A Partial Fulfilment of A Degree Course in Bachelor of Science
(MECHANICAL AND MANUFACTURING ENGINEERING), 62.

9. Nilawar, A., Nannade H.S., Pohankar, A., & Selokar, N. (n.d.). Design of Go Kart.
Retrieved October 27, 2016 from [Link]

10. Nilwar.A., Nannade.N.S., Pohankar.A. & Selokar.N.(2016).International journal for

engineering application and technology design of Go-kart, [Link]/
papers/may [Link]

11. Sivert.A.,Betin.F.,Lequeu.T.& Maeght.F. (2016). Pedagogical study of electric go-

kart: Technological choices, instrumentations, characteristics challenge,
[Link]
12. Yadav, Gautam, Dhananjay, Aakash Ahlawat, and Gaurav Gulia . 2014. "GO KART
DESIGNING AND ANALYSIS." Journal of The International Association of
Advanced Technology and Science 3-4.

13. Mora, J., Romero, L., & Ruperez, M. (2011). Formula zero :Development and karts
competition driven by PEM fuel cell. International Journal of Hydrogen Energy, 1.

14. Wan Mohamad, W., Atan, R., & Sin, Y. T. (2009). CURRENT AND POSSIBLE
FUTURE APPLICATIONS OF HYDROGEN FUEL CELLS IN MALAYSIA.
International Conference on Advances in Mechanical Engineering (ICAME) 2009, 2.
9.0 APPENDICES
APPENDIX 4.1

Where knowledge is applied

International College (UniKL ICOLE)

Notes of Meeting

Date : Wednesday, 12 October 2016 Ref : UniKL/ICOLE/DESIGN3/T6/01

Venue : Lab B109A , UniKL MFI Time : 2000 - 2300 hours

Subject : Design III Project Car Endurance Challenge.

Attendance:

1. Nur Izzul Rafie ( Project Team Head ) 8. Muhamad Asyraf (Lead Test &
Commissioning)
2. Effa Riza Abdul Rait ( Lead Secretary )
9. Nur Azlinda Wati ( Lead QA )
3. Saiful Omri Abd Hafidz ( Lead Designer )
10. Mohamad Shahrul ( Lead
4. Muhamad Amirul Asraf Assistant Lead
Analysis )
Designer )
11. Shahrin Kamruzaman ( Lead
5. Hilmi Suliman ( Lead Procurement )
Assembly)
6. Muhammad Syafiq ( Assistant Lead
12. Amierul Hazzazie ( Assistant
Procurement )
Lead Assembly )
7. Aliff Fitri Afandi (Lead Fabrication)
No Items Actions Feedbacks

1. Go-Kart Theme
a) Based on the proposed project above, the proposed
Go-Kart theme are:
i. Go Green
ii. Endurance
b) Final decision by members, Go-Kart theme are Go
CLOSED
Green & Endurance.
c) Effa suggested the tagline are :
i. Go-Kart for everyone.
ii. Technology you can enjoy.
iii. Wake up and drive.
d) Final decision by members, the tagline is
Technology you can enjoy.

2. Concept Design

a) Main Frame :
i. Shahrin suggested the material for main
frame is Carbon Steel.
ii. All members agreed the material for main
frame is Carbon Steel.
iii. All members decided to use standard
CLOSED
dimension main frame for Go-Kart.
( 800 mm x 155 mm )
iv. Nur Izzul chose Alifs frame design.

b) Power Train :
i. Hilmi suggested to use electric motor
powered by battery as power train.
ii. All members agreed to use electric motor
as Go-Kart power train.
Prepared by: Verified by: Approved by:

EFFA RIZA ABD. RAIT SAIFUL OMRI ABD HAFIDZ NUR IZZUL RAFIE ZAHIDIN

Date: 04 October 2016 Date: 04 October 2016 Date: 26 February 2016

 APPENDIX 4.2

Where knowledge is applied

International College (UniKL ICOLE)

Notes of Meeting

Date : Wednesday , 19 Oktober 2016 Ref : UniKL/ICOLE/DESIGN3/T6/02

Venue : Lab B109 A, UniKL MFI Time : 2000- 2300 hours

Subject : Design III Project Car Endurance Challenge

Attendance:

2. Nur Izzul Rafie ( Project Team Head ) 8. Muhamad Asyraf (Lead Test &
Commissioning)
3. Effa Riza Abdul Rait ( Lead Secretary )
9. Nur Azlinda Wati Sumardi ( Lead
4. Saiful Omri Abd Hafidz ( Lead Designer )
QA )
4. Muhamad Amirul Asraf Assistant Lead Designer )
10. Mohamad Shahrul ( Lead
5. Hilmi Suliman ( Lead Procurement ) Analysis ) 11. Shahrin Kamruzaman
( Lead Assembly)
6. Muhammad Syafiq ( Assistant Lead Procurement )
12. Amierul Hazzazie ( Assistant
7. Aliff Fitri Afandi (Lead Fabrication)
Lead Assembly )
No Items Actions Feedbacks

1
The frame design for go-kart:
a) Discuss what material will be use for our go-kart.
b) Some of the suggestion proposed by the members are:
Closed
i ) Carbon Steel
ii ) Mild Steel
iii ) Steel
c) Final decision made by members, the material chosen is
carbon steel which proposed by Shahrin,.

2
Budget :
a) Budget collected is RM100.00 from each member to Closed

buy hollow carbon steel.

b) Members collect the budget before 17 October 2016.
Car design :
3
a ) Suggestion and opinion for the car design given by
the members before finalizing the design of the car.. Closed

b) All member agreed with the finalized design and

approved by project team head.

Prepared by: Verified by: Approved by:

Nur Azlinda Wati Sumardi Shahrin Kamruzaman NUR IZZUL RAFIE

ZAHIDIN
Date: 20 October 2016 Date: 21 October 2016
Date: 23 October 2016
 APPENDIX 4.3

Where knowledge is applied

International College (UniKL ICOLE)

Notes of Meeting

Date : Wednesday , 26 October 2016 Ref : UniKL/ICOLE/DESIGN3/T6/03

Venue : Lab B109 A, UniKL MFI Time : 2000- 2230 hours

Subject : Design III Project Car Endurance Challenge

Attendance:

5. Nur Izzul Rafie ( Project Team Head ) 11. Muhamad Asyraf (Lead Test &
Commissioning)
6. Effa Riza Abdul Rait ( Lead Secretary )
12. Nur Azlinda Wati Sumardi (
7. Saiful Omri Abd Hafidz ( Lead Designer )
Lead QA )
4. Muhamad Amirul Asraf Assistant Lead Designer )
13. Mohamad Shahrul ( Lead
7. Hilmi Suliman ( Lead Procurement )
Analysis ) 11. Shahrin Kamruzaman
8. Muhammad Syafiq ( Assistant Lead Procurement ) ( Lead Assembly)

7. Aliff Fitri Afandi (Lead Fabrication) 12. Amierul Hazzazie ( Assistant

Lead Assembly )
No Items Actions Feedbacks
The team head divided the task for CAE analysis.
1
1. Shahrul in charged in driver weight on main frame.
2. Saiful in charged in impact accident at front and
back of the Go-Kart.
CLOSED
3. Effa in charged in Welding condition on the main
frame.
4. Linda in charged in the selection of bearing.
5. Amirul in charged in the balancing of axle.
6. Aliff in charged in the acceleration of the Go-Kart.
7. Shahrin in charged in impact accident at both rear
of the Go-Kart.
8. Hazazie in charged power of the Go-kart. (Torque)
9. Ashraf in charged in overall force of the Go-Kart.
(Weight test)
10. Izzul in charged the selection of Bolt & Nut.
11. Syafiq in charged in the vibration of engine.
12. Hilmi in charged power transmission of the Go-
Kart.
Due date : Week 12

Prepared by: Verified by: Approved by:

NU
R
HILMI SULIMAN ALIFF FITRI AFFANDI IZZ

Date: 13 October 2016 Date: 14 October 2016 UL

RA
FIE
ZA
 HIDIN
Date: 17 October 2016

APPENDIX 4.4

Where knowledge is applied

International College (UniKL ICOLE)

Notes of Meeting

Date : Wednesday, 23 November 2016 Ref : UniKL/ICOLE/DESIGN3/T6/04

Venue : Lab B109A , UniKL MFI Time : 2000 - 2300 hours

Subject : Design III Project Car Endurance Challenge

Attendance:

13. Nur Izzul Rafie ( Project Team Head ) 20. Muhamad Asyraf (Lead Test
& Commissioning)
14. Effa Riza Abdul Rait ( Lead Secretary )
21. Nur Azlinda Wati ( Lead QA
15. Saiful Omri Abd Hafidz ( Lead Designer )
)
16. Muhamad Amirul Asraf Assistant Lead
22. Mohamad Shahrul ( Lead
Designer )
Analysis )
17. Hilmi Suliman ( Lead Procurement )
23. Shahrin Kamruzaman ( Lead
18. Muhammad Syafiq ( Assistant Lead
Assembly)
Procurement )
24. Amierul Hazzazie ( Assistant
19. Aliff Fitri Afandi (Lead Fabrication)
Lead Assembly )
No Items Actions Feedbacks

1. Project Proposal

e) CEO , Nur Izzul Rafie assigned the team members

to prepared the project proposal.
Chapter 1 Prepared by Amirul & Shahrul
Chapter 2 Prepared by Alff & Shahrin CLOSED
Chapter 3 Prepared by Saiful & Izzul
Chapter 4 Prepared by Effa & Azlinda
Chapter 5 Prepared by Hilmi & Amirul
Chapter 6 Prepared by Ashraf & Syafik

f) Due date : November 2016

2. Procurement & Project Budget

c) Hilmi asked all members to buy parts by

grouping.
i. All members agreed.
ii. Effa, Shahrul, Amirul, Saiful & Syafik will CLOSED
buy Tie Rod at :
Speed Karting Circuit Sdn. Bhd.
Level 1, Quadrant C, Section 13,
40000 Shah Alam.
iii. Azlinda & Shahrin will buy Bolt & Nut at
:
 Tujusama Hardware Sdn. Bhd.
No. 10, Lot 10842, Jalan Besar,
Kg. Sg. Merab Luar,
43650 Bandar Baru Bangi.

iv. Hilmi, Asyraf && Izzul will buy Bush at :

Sri Kajang Motors.

No. 31, Jalan 4/11 A,
Seksyen 4 Tambahan,
Bandar Baru Bangi.

v. Amirul, Aliff, Hilmi & Shahrin will buy

bearing, Nut, Bush & Oil Seal at :

Ren Hup Motor Sdn. Bhd.

No. 21, Jalan Sungai Chua Taman Hijau,
43000 kajang.

Prepared by: Verified by: Approved by:

MOHAMAD SHAHRUL EFFA RIZA ABD RAIT NUR IZZUL RAFIE ZAHIDIN
NIZAM
Date: 25 November 2016 Date: 25 November 2016
Date: 24 November 2016