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Old 02-07-2018, 03:36 AM
Josh.hymel Josh.hymel is offline
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Default Razor "boom" buggy

So my son was given a razor dune buggy with a set of bad batteries and a bad motor. After discovering the cost of replacing the motor/batteries I decided to modify the cart to run from a 79cc predator. Along with a new motor I was going to put 15inch meaty mud tires on the back and 10 inch tires on the front. Also had to adjust the steering which was way far forward to something a bit more natural.

I cleared the room needed and fabbed what was needed to mount the engine. I had to machine the 3/4 inch hubs to 22mm and make a 5mm key shaft for the rear. Turned new spindle sleeves for the front wheels. Because the kart is so small and I was trying to not cut and modify the frame I opted to stick with the #25 chain and stock jackshafts, so I had to weld a #25 sprocket to a 5/8 clutch.

All worked out well. Until my son got to ride it. Although I was able to get a 6.2:1 final drive ratio on the chain drives, the 15inch wheels meant for very little hill climbing torque. This is when I decided to build a 2 speed gearbox.

I made my go karts 2 speed gearbox using Lovejoy couplings and nesting sprocket hubs into the coupling. Essentially making a "dog" type of clutch system similar to how boats engage gear. The final gear ratio are 5.2:1 and 10.8:1.

Here's some pics
Kens kart https://imgur.com/gallery/HO927
Attached Thumbnails
20160615_113318.jpg   20170203_110137.jpg  

20180126_105516.jpg  
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Old 02-07-2018, 04:51 AM
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Nice!!!! So how does she run now with the 2 speed gearbox? I would personally have just gone for a bigger engine, but that's me
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Old 02-07-2018, 07:17 AM
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You've made my day Ken or Josh or whatever your name is. Thanks.
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Old 02-07-2018, 07:56 AM
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F-ing rights... You made my day aswell...
Please post a few more pics of the trans... Or some views of the parts, shifter and coupler/sprockets...

You've kinda opened a giant can of worms here... Defiantly got people interested...
Nice job...
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Old 02-07-2018, 10:47 AM
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If those are Harbor Freight wheels on the front, get rid of them now! Accident waiting to happen. And it will.
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Old 02-07-2018, 11:29 AM
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Somebody help this genius host his pics here.
This is what we need around here.

Great Job Josh(?)
Do you have anymore projects you've done?
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Old 02-07-2018, 05:21 PM
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I just looked at your pics on the link that you provided. That is awesome work oh the gearbox that you did there!
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Old 02-07-2018, 06:52 PM
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I almost started with that same platform but stopped because of the steering wheel awkwardness and the decent resell value of the original setup.

That gear change setup looks great. Would love to see a video.
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Old 02-07-2018, 06:54 PM
Josh.hymel Josh.hymel is offline
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Sorry about the name confusion. My name is Josh. I am the father of a 5 year old (6 next month) named Ken.
I figure for the number of pics I was posting imgur would be best, if not please let me know a better way.

The front tires are intended to be replaced when the cart is actually operational.
I wish I knew how it drove with both gears. I have bench run it and it shifts smoothly. Unfortunately I have not finished due to weather and lots of overtime.

I did have an older nephew drive it while it was tied into 1st gear and it was quick, misbalanced and sketchy. haha

The steering needs some attention and when I rebuild the front it will add the weight I'm sure will balance it back out correctly.

Here is all the pics I have of the gearbox. I got carried away and forgot to take pics.

Kens gearbox parts
https://imgur.com/gallery/J1zqB
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Old 02-07-2018, 06:59 PM
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How to post pics.

http://www.diygokarts.com/vb/showthread.php?t=735

---------- Post added at 06:59 PM ---------- Previous post was at 06:59 PM ----------

This site will host them so we can all see them forever.
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Old 02-07-2018, 08:12 PM
Josh.hymel Josh.hymel is offline
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Here are hosted pics
Attached Thumbnails
20160607_182840.jpg   20160615_113318.jpg  

20170203_110116.jpg   20170203_110137.jpg  

20170515_185149.jpg   20170515_185155.jpg  

20170113_124153.jpg   20170801_203351.jpg  

20170803_214400.jpg   20170803_214443.jpg  

  #12  
Old 02-07-2018, 08:19 PM
Josh.hymel Josh.hymel is offline
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Here's more
Attached Thumbnails
20170806_113401.jpg   20170806_113316.jpg  

20170806_113325.jpg   20170803_214443.jpg  

20170803_214400.jpg   20170809_181439.jpg  

20170809_181517.jpg   20170806_113411.jpg  

20170816_203143.jpg   20170809_181506.jpg  

  #13  
Old 02-07-2018, 08:23 PM
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This is pretty frickin awesome...
Managed to look at all the pics at home on the comp... Very nice...
I see you even got idler bearings in the sprocket gears... I was wondering how you were going to avoid seizing...
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Old 02-07-2018, 08:28 PM
Josh.hymel Josh.hymel is offline
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And the gearbox.
I dont like how the pics aren't oriented correctly but any who... Here ya go
Attached Thumbnails
20171212_091444.jpg   20171212_091452.jpg  

20171215_202502.jpg   20171212_091506.jpg  

20180126_105505.jpg   20180126_105518.jpg  

20180126_105512.jpg   20180126_105522.jpg  

20180126_105527.jpg   20180201_193456.jpg  

  #15  
Old 02-07-2018, 10:01 PM
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Fyi. The pics are sideways cause you took them that way.
No big deal. We just lay down to view them.
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