Putting Metal Together
Welding Tips for Kart Builders
You don't need to be an expert weldor to weld a go kart. In fact, it can be a good project to learn on. You will need to make strong welds, but if you don't mind spending some time with the grinder, you'll be fine.
If you're a neophyte weldor, we suggest you team up with a better weldor. They'll give you more hints on your style that you can't get from reading about welding.
This is in no way an exhaustive tip or safety list for what you'll need to know to weld a kart, or any project.
A good welding resource are the Weld Talk forums at Hobart Welders.
Welding Zinc Plated and Galvanized Material
If you didn't already know that welding on zinc is incredibly dangerous, you do now. Breathing the vapors can make you very sick, or end your life. This doesn't mean that you can't weld the material, but it does mean that you need to be very careful.
If you don't yet own an auto-darkening helmet, go get one! Harbor Freight carries an affordable, though cheapie feeling one. Whichever one you get, you'll love it. It makes welding so much easier.
Welding Round Tubing
As a matter of asthetics, making a go kart frame completely from round tubing would look better than a frame of round and square tubing. However, using both tubing types greatly reduces your need for prep work on the tubing. Additionally, you'll need fewer tools. More on this subject is in on the materials page.