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Old 02-12-2019, 04:54 PM
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Default My half of the MacGyvers Workshop & The ASAP Automotive Channel Kart throwdown build!

Hello everyone!
This is my part of a friendly Father/Son throwdown project that we will be filming for our respective YouTube channels. I've gotten a huge head start on my son by virtue of finding a donor bike first, and already having a kart that I can build on. It's not a true racing kart, but I feel I can make it work! We will be filming our builds, and posting episodes to our channels. There will be some friendly trash talking and rivalry LOL! We hope it will be entertaining as well as boost our channel viewership. I want to post the pictures here so I can get some "peer review" if you will, as well as maybe catching something I may have missed so here goes!
This is the kart that I built for my Youngest son Niall back in 2012. He got tired of it as the modern karts have suspensions and ride better on dirt. We have much dirt! and gravel. So it pretty much beat you to death while riding it.
I found a wrecked bike on Craigslist not far from me for $250, I went and checked it out, bought it and had him load it up!
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Old 02-12-2019, 05:07 PM
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Default #2 Starting the build!

I cut the kart in half and made a jig on my shop lift so I could keep everything nice and level/even in order to stretch the frame...
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  #3  
Old 02-12-2019, 05:12 PM
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Default #3 Stretching the frame

I extended the frame, and using a tubing notcher, made angled reinforcements that I welded into the frame extension. It is lightweight and extremely strong. Think of the oil derrick looking thing that you built in high school drafting class, and competed by putting weights on it until it finally collapsed. That's what this is. Those 45 degree angled reinforcements really strengthen the frame.
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Old 02-12-2019, 05:23 PM
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Default #4 Mounting the engine cradle from the donor bike.

The donor bike was a 2001 Katana 600. It's not as fast as a GSXR, but after some tuning, it should be pretty quick. I lined up and mounted the engine cradle, and test fit the motor. Also, some parts arrived, so I could test fit the 1.25" axle. I will have to come up with something clever to allow me to tighten the chain as it stretches. All the Gixxer kart builds I've seen so far, only have an idler, which can break when you decelerate into a corner. I know it will cost me in some weight, but I'm going to build in a method of tightening that huge #50 drive chain.
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Old 02-12-2019, 05:31 PM
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Default #5 More parts!

More parts arrived! I have the rims for my 10" wide racing slicks. I figure I'm going to need all the grip I can get.
I also hate the typical "Go-Kart" style steering so I bought a universal Rack & Pinion kit.
And I got a universal instrument cluster that has a speedo, tach, fuel level, and gear indicator built in.
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Old 02-12-2019, 05:44 PM
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Default #6 The chain tensioner

I used my bandsaw to make nice even cuts, then drilled the 2 parts together to make sure they are perfectly matched. There is an angle bracket that the axle bearing will mount to, and thick reinforcing plate that will go underneath the slider assembly. It is all locked together with 1/2" grade 8 bolts. Then you can see the finished product. There will be 3 of them, and they can draw the axle back nice and evenly (I will check it with a tape measure using the front axle as a guide).
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Old 02-12-2019, 05:49 PM
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Default #7 Mounting the rear axle.

I mounted the tires to the rims, and installed the rear axle. I will eventually cut out a good bit of the rear end of the kart. I just left it so I can have it mounted on a makeshift rotisserie. Those tires are huge! No weenie tires on this project!
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Old 02-12-2019, 05:54 PM
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Default #8 Mounting the steering rack

I mounted the steering rack, and temporarily installed the front wheels (I will be putting new front spindles on it later). It's sitting on all her new wheels now! and she looks really good from the side!
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Old 02-12-2019, 06:04 PM
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Default #9 Exhaust header, brakes and roll cage.

I put the motor back in, and installed the exhaust header. I extended the collector out a bit as I will be installing a wide band O2 sensor and A/F gauge as part of the data collector. I installed the brake caliper and rotor, I went ahead and built the drive chain, then I started on the roll cage.
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IMG_20190118_182728.jpg   IMG_20190118_182747.jpg  

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Old 02-12-2019, 06:17 PM
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Default #10 Fabricating the roll cage

I fabricated the roll cage by welding a bracket on to the cage and the kart frame. You can see how they mate together. Once I had the cage the way I wanted it, I mounted the fuel tank, and the oil cooler. It is essentially a large truck oil cooler with a fan mounted to it. I will incorporate a temp sensor that will kick the fan on when the oil temp reaches a predetermined temperature.
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Old 02-12-2019, 06:23 PM
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Default #11 Finalizing the back of the kart, and fitting the seat.

I built a chain guide. I will line it with some plastic so the chain doesn't rub on metal. The roll cage is pretty much finished and ready for blasting and painting. The seat arrived, and I made a heat shield that mounts to the front of the motor.
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Old 02-12-2019, 06:28 PM
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Default #12 fitting the seat.

I realized that I would need to make some modifications to the heat shield as it makes the seat sit too far forward. I added another bend just above the header which allows me to mount the seat an additional 4 inches to the rear. Once that was done, I could start on fabricating the pedals.
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Old 02-12-2019, 06:46 PM
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Default #13 Fabricating the pedals

I had to fabricate the 3 pedals, Throttle, brake and clutch. None of the original stuff would work so I had to order all new parts. The master cylinder was a challenge as I had to make it work around the steering rack. On the MacGyver scale of 1-10, this was an easy 9!
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Old 02-12-2019, 06:52 PM
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Default #14 Steering wheel, and custom cables.

I got the steering column and wheel mounted, then I had to make custom cables for the clutch and throttle. I was able to find a proper length throttle cable I could use, but the heavier clutch cable required a bit of work. It all comes in bulk, so I had to buy 50 feet of the 2.5mm center cable, and outer sheath, as well as all the ends and fittings I thought I might need. I'll share all my extra parts with my Son so he doesn't have to buy the same stuff I did LOL! The cables ended up being about 80" long.
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Old 02-12-2019, 07:07 PM
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Default #15 Instrument cluster mount, and more Parts!

I made a mounting for the instrument cluster that I can view through the gap in the steering wheel. I also got some more parts in! After looking at the kart, I realized that I did not want to have to remove my hand from the wheel to shift gears! so I bought an air shifter kit, and engine kill module that will allow me to shift without using the clutch It should sound something like this video where a guy built a Gixxer kart using a GSXR 600 motor and installed an air shifter.
https://youtu.be/9GKaFKD-Ar4
I also got an air fuel meter that reads off of a wideband O2 sensor, it's also compatible with an AEM Datalogger. With it I can use the optional GPS module, as well as the A/F meter and log my entire track run, and superimpose the datalogger info in sync with the video I shoot during the track run. That will be totally badass!
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Old 02-12-2019, 07:14 PM
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Default #16 Misc. Parts

I got a jet kit, and rebuild kits for the carbs since I will be running K&N filters and a straight pipe exhaust. I got a switch panel to control the start functions of the motor, I then installed the diamond plate floorboard, and test fitted the air compressor for the air shifter.
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Old 02-12-2019, 07:22 PM
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Default #17 Throttle cable, Sandblasting booth and painted frame.

I realized that I needed to finalize the fabrication of the throttle cable, then I stripped the entire kart down for blasting. I built a small blasting booth as the sand will go everywhere if you don't! Then we have the primed and painted frame!
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IMG_20190203_191330.jpg   IMG_20190203_191252.jpg  

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Old 02-12-2019, 07:30 PM
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Default #18 Racing clutch install, chain guide, and starting the assembly.

After letting the paint cure for a day, I installed a carbon fiber racing clutch as the original was pretty much worn out. I riveted some plastic on to the chain guide so the chain won't rub on metal. Then I reinstalled the motor and installed the heat shield that I painted with high temp. ceramic exhaust paint.
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Old 02-12-2019, 07:35 PM
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Default #19 Roll cage, GPS module, and floorboard

I blasted, primed and painted the roll cage with the frame (the crossbar for the 5 point harness is now welded in), I then mounted the GPS module top and center of the cage, then I installed the completed floorboard, and reinstalled the pedals.
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Old 02-12-2019, 07:43 PM
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Default #20 Air shifter install.

I used the top mounting boss on the rear of the motor to fabricate the top mount for the air shifter cylinder. Then used a "Heim" joint to connect the other end to the shifter lever. It was really convenient that it was a perfect 5/16" so I could use a 5/16 die to thread the peg and install a 5/16 locking nut to secure the bottom of the shift cylinder. And of course I mounted the air compressor to a plate behind the seat.
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