Bodge Charger 2

Bodge Charger 2
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Built By	Vince Williams
Theme	Bodge Charger 2
First Race	Footfest 2024
Current Status	Active
Motor	2x 2kw Brushless BOMA, AliExpress
ESC	2x 1500W 48v ebike Generic controller, AliExpress
Battery	48V 12S Li-Ion module from an eGolf EV
Gearbox	None
Contact	@Bodgecharger
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Background

Bodge Charger 2 was developed from a combination of the original Bodge Charger (circa 2020) and lessons learned from ACDC (a very successful low ground clearance racer best suited to tarmac / concrete / flat and smooth short grass circuits, but some of the tracks we race on throughout the year can be held on rougher ground such as bumpy fields or meadows with medium to long grass. So Bodge Charger 2 takes into account all the lessons learned from these two Hacky Racers and incorporates them into the new Bodge Charger 2. These first set of pictures show the original Bodge Charger Hacky Racer as it was in 2020/21 at the very first Scrumpy cup and then at fully charged Live at Silverstone.

I also wanted to see what could be improved on regarding power, traction, stability, differential and batteries and have addressed each of these topics in the design. So I've now included full suspension (independent on the front, single swing arm on the rear), twin 2kw motors one on each rear wheel (split rear axle), electronic Diff, and a 48v 12s EV battery module from an eGolf.

Construction

Motor

Controller

Batteries

The battery module is a single 12s pack originally from an eGolf EV. As you can see from the photos I've removed the original BMS board and split the pack into two 6s configurations. The battery as it comes is made up of 12 standard 4.1v Li-Ion cells housed in a sturdy metal container with a BMS PCB fitted on top. But seeing as I already have a powerful Dual 6S balance charger, then it made sense to split the pack into 2x 6S modules and get rid of the redundant BMS PCB and just charge the pack in balance mode as I normally do with my old 6S LiPo packs. So I wired up the pack as 2x 6S modules and connected balance leads to all the cells so that it would connect to my charger. To use the pack in its 48v 12S mode then all I needed to do was to connect the two 6S sub-packs in series again for racing with an XT90 adapter I made up.

Drivetrain

Awards

Not Raced yet, just testing!

BOM

Bodge Charger 2 BOM	BOM	Notes
Chassis frame	£20.00	Bed frame
Donor Vehicle	£22.50	eBay, original Bodge Charger
Tyres	£-	included with Donor Vehicle
Wheels	£-	included with Donor Vehicle
Seat	£-	included with Donor Vehicle
Bodywork	£25.00	Googly Eyes, plastic pipe, carboard, stickers.
Brakes	£-	MTB Hydraulic brakes
Steering Rack	£23.78	Ali Express Rack and Pinion
Steering Wheel	£-	included with Donor Vehicle
Steering Wheel Shaft	£-	included with Donor Vehicle
Front Suspension	£13.00	2 Shocks from Mobility Scooter
Rear suspension	£13.00	2 Shocks from Mobility Scooter
Motor	£106.78	2x 48v 2kw Brushless motors
Motor Controller	£31.80	2x 1500w Brushless motor controller
Axle	£16.24	20mm hollow shaft
Axle bearings	£24.44	Pillow bearings
Collars	£5.30	Adapters for Sprockets
Nut & bolts	£20.00	Various
Switches	£10.77	2x power switches, reverse switch
Battery	£-	E-Golf Battery Pack
Sprockets	£21.98	2x 74 tooth sprockets
Chain	£-	included with sprockets
Electronic components	£15.24	ESP32, ADC1115, ADXL345, Connectors etc
Throttle pedal	£16.78	2x throttle pedals
XT90 connectors	£5.00	XT90 connectors
MT60 connectors	£3.00	MT60 connectors
Wiring	£20.00	Various
Brake Return spring	£-	Classic car throttle return spring
Isolator switch	£-	XT90 link
Total	£414.61