Potentiometer Controlled Handlebar

This is a handlebar that can be used to control motor speed which may be used for an electric go kart.

• 1 16X1mm aluminium tube approx 150mm long
• 1 12X1mm aluminium tube approx 150mm long
• 1 linear rotary potentiometer with slot
• 4 M3X50mm bolts and paired nuts
• 3D printer
• Saw
• Tape
• Liquid nails

This step prepares the pipes

• Cut both of the pipes to 100mm in length using a saw
• File edges to ensure they are not sharp
• Cut a small piece of excess sheet metal off and the cut a slit in this ring. Then flatten the sheet so that it is not bent. trim this piece of metal to be a small notch of measurements: 6mmx12mmX1mm

3D print the parts in the attached .STL file

• Print the file using a strong material such as PLA
• Tidy up parts where required
• Glue the aluminium notch into the shaft groove

• Place the potentiometer so that the shaft goes through the main hole and the small notch goes into the smaller hole of the 3D printed plate with two holes in it.
• Screw on the washer and nut that matches the potentiometer to hold the plate in place
• Put the second plate that has the extruded spout on top of the nut.
• Place the potentiometer with the two plates on top of the handlebar connection piece and use 4 M3 bolts to hold these pieces together using the 4 holes in each plate. Ensure any required wiring is connected to the potentiometer in this step
• Attach the 12mm aluminium tube on the spout using liquid nails or glue.
• If the two pipes feel too loose when inserted, you may wrap the inner pipe in some tape such as masking tape to reduce the tolerance
• Insert the shaft with the aluminium tab into the larger pipe so that it is tight, glue this together if necessary.
• Place the larger pipe over the smaller pipe with the shaft inside. Line up the tab with the groove in the potentiometer slot.
• Glue the rings around the pipes to fix them in place and hold the handlebar together
• Connect the extruded cylinder to a steering column as desired.