I have a covered wagon I built using the wheels and axels of a garden cart. (See attached pics) I want to motorize it to make my life easier. I use it at the Houston Livestock Show and Rodeo to provide food for my team of volunteers. I have to take it quite a good walking distance rain or shine. It is 2x4 foot with 10 in wheels. Run time is approximately 3 to 4 hours a day (going in the rodeo and leaving) with an idle period of 6 to 8 hrs between.
Do you want the cart to go forward only, or have forward and reverse?
Thanks for that information. I switched it from a 450 Watt motor to a heavy duty 600 Watt motor to handle the extra weight of the food. At walking speed the 600 Watt motor will be able to easily handle the weight of the food and be able to climb ramps and hills when needed.
The 3-4 hour run time will require a lot of battery capacity so the wagon will need to have three large batteries. I ran some gear ratio calculations and found that with the 10" tires it will need a 45 tooth wheel sprocket. Here is the gear ratio calculation:
We can supply all of the electrical components. The #420 chain and 45 teeth sprocket for #420 chain can be purchased from almost any motorcycle parts store.
Right now finding the right throttle for the wagon is my next goal. I have a couple of questions:
Of course you are welcome to use the 450 Watt or 600 watt motor instead, these parts are only my first suggestion.
How does this parts list sound. Would you like for me to make a kit out of the parts listed above, or make any changes?
I made the kit with the 450 Watt motor. I included a mounting plate for the motor which will make fabricating a bottom bracket for the motor much easier, or the mounting plate alone may work for mounting the motor. With the wagon's 10" wheels the gear ratio of the motor and sprockets in the kit will provide a 3.36 MPH top speed. I included a 100 links (50 inches) of chain which is common bicycle chain and can be made smaller with an inexpensive bicycle chain breaker which can be purchased at any bicycle store.
Attaching the sprocket to the wheel should be the most challenging (and fun) part of installing the kit. The sprocket could probably be attached by bolting it to the wheel with standoff spacers made of steel pipe as shown in the photo below. If that does not work then just about anyone who works with steel would be able to figure out a way to bolt or weld the sprocket onto to the wheel.
If you have any questions or would like any changes made to the kit please let me know.
I made a kit with the 350 Watt gear motor. I had to change the wheel sprocket from 44 tooth to 36 tooth because the 350 Watt gear motor has a lower gear ratio and with the 44 tooth sprocket the top speed would have been 2.5 MPH. With the 36 tooth sprocket the top speed is 3.13 MPH.
Here is the link to the kit with 350 Watt motor:
Please let me know if you have any questions or would like any changes made to the kit.