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  #121  
Old 12-30-2019, 06:00 PM
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JTSpeedDemon JTSpeedDemon is offline
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Yeah, cheap chain links really suck. Good to know that it's not just half links!
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  #122  
Old 01-01-2020, 09:01 PM
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Happy New Year all.

<Edit> Here is my test and tune video compilation (~10 minutes of yard track footage in November and December)
https://youtu.be/YlGP0D15dGM

My final update from 2019 is that we took the yard kart to an offsite location to drive on a .45 mile loop around a recently excavated area.

We have helmet cam footage (really a dash cam) but it is all upside down, and will take some time and editing software to process into a video.

It was good to ride in a wide open space as the sun was setting for the last time on 2019.

Photos show our yard mud on tires yesterday afternoon and different mud that what we brought back from the ride (it was dark when we got back so the third photo was from today)

To the staff at DIYGC...Thanks for hosting the site and having the build off contest. It has been a great learning experience and my son likes karting as new hobby besides his usual computers and tech stuff.




Tech specs go here:

DIYGC 2019 Thunder – gegcorp2012 Yard Kart Therapy


Specifications

Type: Fully suspended yard kart
Weight: 300 lbs(190 lbs rear 110 Front)
Wheel base: 73 inches
Front track: 46 inches
Rear track: 43 inches
Front tires 18x8-7 Maxxis AT
Rear tires Kenda radial 20”
Engine: Predator 212 CC stage1 prep
Clutch TAV2 CVT clone 6”/7”
Genuine Comet belt
Sprockets 10t/60t #40 chain
Frame: 3/4” pipe, pie cut bends
Seat: Plastic racing bucket
Steering: ATV 110 CC with 3” arms and Ackermann set for new wheelbase
Steering wheel: Kandi kart
Front suspension: Dual A-arm coil over ATV 110CC - Peace Sports
Rear Suspension: Monocross ATV 350 CC - Yamaha Warrior
Brakes: 110 mm Peace OE disks on front, ___ mm Yamaha single disk on back
Master cylinder:Two piston with stop light switch
Drift/parking brake: Modified Yamaha rear foot pedal assembly

GPS verified performance with 254 pound rider:

Carb Jet, air cleaner, header pipe
30 MPH on pavement (with governor... took a long time to wind up)
18 MPH on yard track (with governor)
Governor deleted
41.45 MPH on pavement (4750+ RPM)
26 MPH on yard track (no governor, 6" driven)

KartInfo link
3800 RPM 6"/7"
KartInfo by kartcalc.net:
Code:

KART
Kartname : gegcorp2012 DIYGC Thunder RW diameter : 20 in Weight : 554 lbs
ENGINE
Engine type : Predator 212 HP : 6.5 Torque : 12.86 Nm | 9.48 ftlb RPM : 3800 Governor removed : true Assummed HP : 6.66 Mods : carb jet, header, air filter
TRANSMISSION
System : Torque Converter Clutch sprocket : 10 TC type : series 30 7" driven TC sprocket : 10 Axle sprocket : 60 Final Ratio : 6:1 Lowest Ratio : 18.78:1 Highest Ratio : 6.72:1
PERFORMANCE
Min Torque : 86.42 Nm | 63.74 ftlb Max Torque : 241.51 Nm | 178.13 ftlb Acceleration : 2.12 m/s | 6.96 fps Top Speed : 54.15 km/h | 33.65 mph
__
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5500 RPM 6"/7"
KartInfo by kartcalc.net:
Code:
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KART
Kartname : gegcorp2012 DIYGC Thunder RW diameter : 20 in Weight : 554 lbs
ENGINE
Engine type : Predator 212 HP : 6.5 Torque : 12.86 Nm | 9.48 ftlb RPM : 5500 Governor removed : true Assummed HP : 7.25 Mods : carb jet, header, air filter
TRANSMISSION
System : Torque Converter Clutch sprocket : 10 TC type : series 30 7" driven TC sprocket : 10 Axle sprocket : 60 Final Ratio : 6:1 Lowest Ratio : 18.78:1 Highest Ratio : 6.72:1
PERFORMANCE
Min Torque : 86.42 Nm | 63.74 ftlb Max Torque : 241.51 Nm | 178.13 ftlb Acceleration : 2.12 m/s | 6.96 fps Top Speed : 78.37 km/h | 48.7 mph

Last edited by gegcorp2012; 01-02-2020 at 12:14 AM.
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  #123  
Old 01-07-2020, 11:45 PM
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Quote:
Originally Posted by gegcorp2012 View Post
To the staff at DIYGC...Thanks for hosting the site and having the build off contest. It has been a great learning experience and my son likes karting as new hobby besides his usual computers and tech stuff.
You are welcome It is just awesome seeing people getting into the garage and building things!!
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  #124  
Old 01-20-2020, 11:14 AM
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Update : New 4 lug wheels and tires, front suspension rebuild, better brakes.

With the 2019 build-off in the rear view, its time to look down to road and upgrade the Yard Kart for more safety at speed and better handling.

Understeer was the biggest issue at >20 mph on grass with the very worn tires on the front and the large paddle tires and live axle on the back.

The repeated thrashing on the yard track and 30+ MPH runs on a chert excavation site has flushed out the need for 4 lug front rims, better tires and new bushings on the control arms.




Look at that slop !

I replaced the worn and sloppy bushings with CPVC fittings that pressed right in and just needed to be drilled amd cut down to fit.




I used the CPVC fittings because that was the closest thing I could find at the local hardware supply, and these will eliminate all of the slop. That is a fix in my book.

Next stop is brakes:

Something is not right with this caliper, since the outer pad is showing a contact patch less than half of the size of the pad. It may be the casting is not square or the pad is rocked out a bit.

I am waiting on 128mm brake rotors for the new hubs, and I also have a better master cylinder to do next.

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  #125  
Old 02-04-2020, 07:50 AM
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The 128mm rotors came in last week and quite naturally did not work with the existing 110mm calipers... so I had to order couple of different caliper sets until I got the right ones.

If you are considering using Chinese ATV suspension and brake parts, be sure to skip the 50/70/110 cc class parts and start with the 125/250/300 cc class parts because they are beefier and more suited for the extra weight and stresses the kart will generate.



I chose to modify my uprights to hold the new calipers as the new parts result in a wider arrangement.

I drilled 4 short pieces of 1.5x3/16 flat stock to make new caliper mount brackets and assembled for a test fit, then tacked them on. I removed the calipers before bringing the heat.



I will brush them down and trim them so they look better and paint them next.



Also changed the mounts for a new 3/4" bore Polaris master cylinder for plenty of volume and line pressure.



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  #126  
Old 02-04-2020, 10:46 PM
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Looking good!!!
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