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  #41  
Old 05-27-2016, 08:18 PM
Ean Gdaniec Ean Gdaniec is offline
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Default My DIY Kart

{"1964 Bug Sprint"}(The frame, steering rod, tie rods, spindles, and steering wheel and pedals are original)

{Custom build/built by me, my dad, Tom, Tom, and the frame was given to me by another Tom}

{Kawasaki/5 HP/181cc}(for potential comparisons)

{40 tooth or 60 tooth/4-1 to 6-1/front= 12-6x6, rear=15-6x6}

{ON road usage}






ATTACHMENTS:{4 pics(minimal) of the kart from the 4 angles}(low front, high front corner, low side, and hi


The frame was extremely rusty, had four paint-jobs underneath. Took a month to professionally sand all parts and frame down to bare metal (I have a busy schedule). Unfortunately the seat was extremely damaged with minor holes and pits, but it will hold the driver. The body and parts were primed, then painted, while some parts were shined, then glossed. Bolts were bought to hold the tie rods onto the column, and two large bolts for the frame to the spindles. The spindle and tie rod connections were bolted, and nylocked, while the center bolt where the tie rods meet with the steering shaft was a custom drilled bolt for a cotter pin.My dad’s friend had a few spare engines to give: A 5 HP Kawasaki(kawasaki outputs are different, so it probably gives out 6.5)with an organ donor, and another engine that doesn’t matter to the story, he also had spare rims. Soon later, a new friend Tom (who I made good friends in this) had 4 spare tires, 12-6x6. They were a perfect for for the rims. A friend of mine had a clutch, 40T gear, chain, clutch oil guard, and axle bearings(2) for the kart. Me and dad worked on a real size replica of a swing mount, and over time it was constantly modified(It was built of hardboard and glue from a hot glue gun). We bought bolts for the axle bearings. I bought an axle with keystocks and a pair of the wrong rear rims, so I returned them and bought off of ebay (Jed’sWholesaleTires) a pair of rear rims, 1in center bore diameter with key hole slots. Shortly after, I had bought 15-6x6 rear tires slick. I sprayed painted the rims after a soft sanding was done to the original paint prior to painting. We then baked the rims in our home oven (for high quality paint adhesive). After that, we bought a washer, lock washer, and lug nut for each side. It’s finally rolling, and after some clean up with the steering wheel, because it was badly weathered chrome, I put that back on the steering rod with the mid-sect, whatever that is called, and bolted the two bottom with the original cotter pins, then placed the original lock nut to secure the rod from sliding down. We bought a Bug dual brake bracket with a whole disc brake assembly, after its shipment, we went towards building a replica sized hardboard for the caliper bracket. We bought cables soon after and mounted the brake cable up, in the process of using one steering wheel bolt with the cotter pin for the connection to the pedal, and we bought earlier, a few extra clamps, and on the other side, had the throttle cable ready. We brought the new replica brake caliper holder to our new friend other Tom, and he made it in a few weeks. We quickly assembled it and the brake was ready. We custom fitted the spring, housing tension, inner housing tension with some things like the inner housing running through a bolt of the brake lever, then tightened with two bolts and two washers. After this, we soon gave other Tom our swing mount replica, and waited. While our waiting after 2 weeks, we went to Kralz scrap yard and bought what was a very large aluminum plate, 3/16 inch thick, all for a very cheap price. We cut it to size using a jigsaw. We slid it into the kart, then marked where the holes for bolting needed drilling, then, after drilling, We polished using two polishers, the first, a rougher polishing compound, then a fine polishing compound. After that, we bolted the allen bolts in and threaded with nylock, then added stickers (adding stickers happened dead last after everything for touches). The original parts were repainted, chrome paint, then a gloss, the engine was painted and those parts were baked on low in our outer grill, and other parts on it were appropriately painted chrome.The throttle was clamped on, but it was difficult to modify the odd japanese throttle back, idle, governor, and spring. We bought and cut to length the fuel line, got a fuel tank, cut out, drilled, and had other Tom press bend a crease in the will be fuel mount. After that, we bought all the remaining bolts necessary, extra locking collars, spacers with set screws, and finally, days later, the mount was completed. We bolted and set to fine measure everything on the back. For suppressing the vibration, we used tightly folded, thin rubber, then placed it between the frame and the underbelly of the back of the mount, and added zip ties. We mounted the engine, set the 60 and 40 tooth on in case we want to change gears (5 min manuel change), chained up the gear to the clutch, bolted the clutch in (the set screw was almost useless). We tightened everything again, bolting the fuel tank in the mount, cleaned the oil, filled the gas, and we were ready. The number plate was made a bit before the final product, custom cut and grinded aluminum with only white primer, 7 by 10 in. , with purchased number plate sticker decals, 64, in honor of the year of the frame and other small parts, almost perfectly center, with only 1/32 margin error, bolt holes were measured, then drilled, then fitted with allen wrench bolts with nylon washers, and nylock ends. The whole project over ten months to complete, mostly because this was my first time ever building anything, and my dads first on a kart, and me and my dads schedule in between.
Other: There was originally, a temporary fuel mount, that was bolting the bottom of the fuel tank, so the tank stood up, which was ugly, that and the mount only had one hole to bolt to the engine. It broke during one of my runs, having the gas tank fly off, and burned against the muffler. The number prints was added on later after the few first drives, including the stickers, adjustment of the brake, and rubber mesh underneath.
Attached Thumbnails
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20160507_010619.jpg   20160523_210637.jpg  

20150725_193045.jpg  
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  #42  
Old 05-27-2016, 08:26 PM
Ean Gdaniec Ean Gdaniec is offline
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Default Other angles of my kart

Some other angles, and some of these pictures are older, so it shows the state I went through before its finish.
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20160507_010500.jpg   20160424_152427.jpg  

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  #43  
Old 05-28-2016, 10:54 PM
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Buildoff barstool racer from 2014 I did...............
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  #44  
Old 05-28-2016, 10:55 PM
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Buildoff adult sized big wheel for 2015...........
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  #45  
Old 09-08-2016, 07:50 AM
SEL SEL is offline
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Default My kart

Baby

Margay Tsunami 100 '95

Predator 6.5 212cc non-hemi

12 tooth to 69 tooth. 10x4.5x5 11x6x5

on road = pavement pounder

Mods:
-angled air filter and filter cup
-.036 jet and bored out emulsion tube
-started with a HSK single stage header but swapped out for Robertson Candy Cane three stage
-governor removed, low oil sensor removed
-Black Rhino 15 degree 4 cycle engine mount
-Comet TAV-30 torque converter 12 tooth
-69 tooth sprocket on CKS billet aluminum sprocket hub

My rebuild, not restored, Margay race kart. Bought as a "rolling chassis" and came with original Yamaha KT100 and wet clutch, will be rebuilding that....someday. It took me about five months to get her back on the pavement and runs great, in my opinion anyways. It was my very first time rebuilding a kart and modding a small engine. Had fun doing it and looking forward to rebuilding my next one.

Video:
https://youtu.be/DcdhLZSDbX0
Attached Thumbnails
Night I brought her home.jpg   Day 1 001.jpg  

Day 1 002.jpg   Predator 212.jpg  

Complete - front.jpg   Complete - left side.jpg  

Complete - back.jpg   Complete - right side.jpg  

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  #46  
Old 11-02-2016, 07:12 PM
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Quote:
Originally Posted by bshinn View Post
And as it sits now, BTW it's an 84 Margay Xpert-II according to Keith at Margay. It's been a 2 yr odyssey to this point, the plan for the winter is a final teardown frame mods, powder, & chrome, then it should be finished.

Would like to find some original Series 62 wheels/hubs, if anybody has lead please contact me.

Even with just a KT100, it's amazing how fast this thing is with my 48yo 6'0" 230# A$$ on it!
It just so happens that there are kids on this forum

---------- Post added at 08:12 PM ---------- Previous post was at 08:11 PM ----------

Although, I've nothing to post here
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  #47  
Old 01-01-2017, 09:49 PM
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Quote:
Originally Posted by Hybridyne View Post
Got my two army mules completely done this weekend. One is all electric and the other has a Honda 125cc Motor with electric start and reverse.

Fun Project !!!

Hats off to Dewies


Those are my new favorite! I've never seen anything like it. Did you design it?


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  #48  
Old 04-05-2017, 12:30 PM
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80s modified fl250 Honda Odyssey.
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  #49  
Old 04-09-2017, 09:09 AM
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My fully rebuilt 2007 Baja Sand Dog converted to a woods bouncer.

I lifted the front end shock mounts 3" and put some longer shocks with softer springs for much better front end suspension setup (she floats nice now).

Original 196cc tecumseh got tossed. Put a 420cc predator, Vegas karts tuned carb, removed governor, High flow header with Fart can, 8 flywheel timing advance key, 44 Magnum driver clutch, Max torque 7.5" Driven clutch with 12T/70T gear ratio. Running on 22" ITP Mud tires in 20" ATV all terrains up front.
Original hydraulic disc brKe in rear nothing in front yet but will putting ATV system for brakes.. possible motor swap to 2 stroke 440cc Arctic Cat engine this spring.. it's a monster but I want the front wheels off the ground

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  #50  
Old 05-12-2017, 11:19 AM
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I've mostly finished the little Wasp. Based loosely on 1911 Indy winner The Marmon Wasp. 500 miles @ 74 mph.
Scratch built, steel tube frame 1" X 3" Honda 17" wheels, 6.5 clone TAV, 11 & 60 sprockets, Running gear uses mostly go kart parts 1" live axle, hyd. disk brake, Body 4mm plywood, Runs about 40 mph & is a blast to drive, weight around 250 lb.
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P1030782.jpg   P1030791.jpg  

P1030841.jpg   P1050227.jpg  

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  #51  
Old 07-03-2017, 05:00 PM
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Tom Knight, Love the project turned out great! Did you build with a set of plans? I would really like to build one as well.
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  #52  
Old 09-11-2017, 05:23 PM
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It started as a small Manco frame. I shortened everything so a 5yr old can fit on it.
3hp Briggs Flat head
12T clutch
80T sprocket
#35 chain
4.10x3.50-4 inch wheels in front
13x5-6 inch wheels in back
I used the seat, engine mount plate, steering column, and spindles from the original Go Kart. I shortened it up, and built a new frame for it.


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  #53  
Old 09-12-2017, 01:06 AM
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Awesome build!!! That little kart looks killer in yellow. Well done
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  #54  
Old 09-12-2017, 01:44 AM
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I really liked everyone projects, mine chainsaw is in progress will be posting it soon.
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  #55  
Old 11-01-2017, 07:24 AM
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Quote:
Originally Posted by Mike_D View Post
Pics of my Clark Cyclops 440 restoration. My cart from early 1980s, spent countless hours and summers riding it. Restored so my son can ride it again (in a few years). Added the pipe behind the axle under engine plate and strengthened the joints on seat pan. All that's left is to get a new seat made.
VERY COOL MIKE D! Passing it down to your son.
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  #56  
Old 08-02-2019, 12:04 PM
TKart23 TKart23 is offline
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1990 Manco 405-00
New: Motor, Seat and Tires
Everything else is orig.
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20190801_210821.jpg   20190802_084251.jpg  

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  #57  
Old 08-02-2019, 12:24 PM
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First is before second is after still not 100% done but its restored
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  #58  
Old 08-13-2019, 01:48 PM
NewbCarter NewbCarter is offline
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1994 Swiss Hutless Rondo. Engine is an IAME Parilla TG14.
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  #59  
Old 08-20-2019, 02:35 PM
MancoCooper MancoCooper is offline
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Default Manco Magnum Express Project

Manco 606 that sat in a field for 2 years. Rebuilt from frame up for my son, still a work in progress but it's a blast.
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IMG_4150.jpg   IMG_4159.jpg  

IMG_4160.jpg   file.jpg  

file1.jpg   file2-3.jpg  

file3-2.jpg  
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