That is a great idea for us to make to make a chart showing all of the different options and possibilities for making a beach wagon. I am already starting to form an idea of what the chart will look like. I will start working on making a beach wagon build chart and post it on our website when it is finished. This way when someone starts a build I can refer them to it to make the planning process easier.
I recently spent a few days building a customer service counter for our warehouse and after it was finished realized that it was too low and needs to be higher. So I basically have to start over and build it again. The top is the only part that can be reused. I purchased the wood needed for the rebuild yesterday. So I know the frustration of building something that was not designed as it should have been from the beginning.
Unfortunately all of the thumb throttles we have slip over the bar and do not come apart for mounting onto a closed handle. The best thumb throttle and easiest to integrate into the kit that I can think of is one that we have with a built-in battery power meter and a latching on-off push button switch which we could wire as the main power switch. Here is what it looks like.
Does this throttle and the idea of having the power switch on the throttle sound like a good idea to you?
From your description of the beach cart needing to travel 250 yards each way with a slight incline in one of the directions I calculated that two 12 Volt 12Ah batteries would have a surplus of capacity to do the job so this is the size of battery that I recommend. These batteries are 6" x 4" x 4" each and there are two of them. Is this battery size okay with you?
Before I make the kit I would just like to confirm if you need the freewheel to engage in the clockwise or counterclockwise direction?
I have the kit prepared and it is item # KIT-328-D. Here is a link to it:
The kit would cost $30.00 less with two 8Ah batteries compared to the two 12Ah batteries that it has now. Please take a look at the kit and all of the parts in it to make sure I included everything that we discussed.
If you would like any changes or additions made to the kit please let me know.
The freewheel adapter was gently threaded onto the freewheel by hand for shipping so these two parts would not require two separate bags and to show how they thread together. The threads were not tightened so the adapter can be separated from the freewheel by unthreading it out of the freewheel by hand. You will need to grip the inner part of the freewheel in order to keep it from rotating when unthreading the adapter. The red arrows on the photo below show the directions to turn the freewheel and adapter to unthread them from each other.
The small plastic piece is a spacer that goes over the handlebars and inside of the outside end of the throttle to separate it from the rubber grip. This spacer prevents the rubber grip from catching on the throttle and not allowing it to return to the zero throttle position after it has been engaged.