New Kart Project

[TraderJack]

Hello all,

I stumbled across the site and thought I'd say hello.

I've never built a kart before. I'm handy with a welder and basic tools and I have an 11 y/o son who wants a 4-wheeler. He had a Chinese made kart but it fell apart in the first week. There's only so many times the steering mechanism can be re-welded. When the motor mount shifted by 2 inches that was pretty much the end of the story. Gave that one away and now he has a minibike.

The minibike has the centrifugal clutch and he likes that. So, I'm going to build a cart based on that idea. I've settled myself with the following: Big mudder tires all around for traction and smoother ride. We have 5 acres to tear up. Live axle system. Heavier than normal with more horsepower. I have recently bought (but not yet received) a 16 hp horozontal engine with 1 inch shaft and 1/4 inch keyway. I have a lead on an appropriate clutch and am investigating that.

As I'm laying out the plans I've come across a question: Will the standard 1 inch live axle that I've seen for sale at Northern tools be strong enough for a kart designed to carry a 250 lb. person?

Thanks for any input.

-Jack

[robertdjung]

That's a good question -- I have never built a live axle, so maybe someone with some live axle experience can help out. But I'd be willing to say that it would probably be beefy enough.

Where did you find the clutch? is it one from northern, or somewhere else?

[TraderJack]

Where did you find the clutch? is it one from northern, or somewhere else?

The clutch is available from an acquaintance. I'm hunting for steel tubing to build the frame. Had a lead today but it vanished. I use Craigslist for most of my projects and tools. I've had good luck there.

-Jack

[robertdjung]

if there's a scrapyard near you, you might be able to pick up lots of the "drop" metal for cheap.

[TraderJack]

if there's a scrapyard near you, you might be able to pick up lots of the "drop" metal for cheap.

Good idea but I like to work with the square tubing. I have some angle iron but it's too large for this project with a few exceptions. No junkyards nearby.

-Jack

[TraderJack]

Just an update on my project. I have decided to use a belt drive setup for the drive system. The clutch I am working on getting will have a cog belt drive sprocket. After I get it then I'll need to find out what the size belt it will require is. Are there any good sources for the cog belts that may have photos of the items? I'm also going to need an axle sprocket to accept the belt.

Thanks,

-Jack

[mikeandike]

about the 1 inch axel, my go kart has a 1 inch and when i stand on it it flexes abit and im only about 110lbs but weight distribution might be different when your sitting down... well if your going for a 1 inch i suggest using a third bearing near the middle or on the other side of ur sproket (from the engine)

[TraderJack]

about the 1 inch axel, my go kart has a 1 inch and when i stand on it it flexes abit and im only about 110lbs but weight distribution might be different when your sitting down... well if your going for a 1 inch i suggest using a third bearing near the middle or on the other side of ur sproket (from the engine)

I saw a center type bearing for sale recently but it seemed expensive for my project. If I have a lot of flex in the axle then it will be necessary.

-Jack

[buzzwest]

you don't need a middle bearing if the length between the two outside bearings is not really spread. ithink, check that.
but the a middle bearing is the best/safest way to go.
hope this helps.

[TraderJack]

Since I've never built a kart before....this may seem like a silly question. I saw on another post a question about placement of the engine as related to the sprocket. From the start I've assumed that the engine would sit between the seat and the axle. Is this the usual arrangement?

Thanks,

-Jack

[philip metzner]

hi, i was just reading about your kart project, and i think you should go with 1 1\4 axle with your wieght and horsepower. you can get axle and hardware from american power sports. www.apskarting.com, i think. those belts and belt gears are expensive!!!!--phil

[TraderJack]

hi, i was just reading about your kart project, and i think you should go with 1 1\4 axle with your wieght and horsepower. you can get axle and hardware from american power sports. www.apskarting.com, i think. those belts and belt gears are expensive!!!!--phil

I've ordered the 1" axle and it should be delivered soon. If it's too weak even with a an extra center bearing/support then I'll upgrade to 1 1/4". Are they made larger than 1 1/4"? Maybe 1 1/2 or 1 3/4 would be better?

-Jack

[mikeandike]

i think more than 1 1/4 is overkill

[kart62]

Your axle size of 1 inch should hold up okay due to the bigger tires, what I mean is the tires will absorb the beating before the axle takes abuse. If it does end up bending go with a 1 1/2" tube steel axle next go around, there stronger....I dont know how to explain it but they are.

[PJG1173]

Jack,
the current project kart I am working on now has a 100cc dirt bike engine with a 1 inch live axle and 22 inch atv tires. It is the stock axle that came on a Yerf dog kart. With two adults there is no noticeable flex in the axle.

[robertdjung]

pics! pics!

[PJG1173]

Here are some pics when we first built it. Since then I have redone the front and rear suspension. More pics when I get a new camera.

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[TraderJack]

Jack,
the current project kart I am working on now has a 100cc dirt bike engine with a 1 inch live axle and 22 inch atv tires. It is the stock axle that came on a Yerf dog kart. With two adults there is no noticeable flex in the axle.


Thanks for the tip. My axle arrived and it looks plenty strong. My wet clutch also arrived...it's huge! Still waiting for the chinese-made 16 hp engine. When it arrives I may post some pics of the components. This is my first kart project so everything I make is going to be "prototype" until I'm satisfied with the design.

-Jack

[2or3wheels]

thats an awoesome kart

[PJG1173]

please post some pics when you can I would like to see that wet clutch.

[TraderJack]

please post some pics when you can I would like to see that wet clutch.

Will do. If the weather stays dry for a few more days then I'll be able to kick production into higher gear.

-Jack