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Old 08-16-2019, 12:41 PM
Forker45 Forker45 is offline
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Default Carter Live Axle Conversion + More

Hello all! I originally intended to create this thread in early July and update it as the project progressed but I got hung up in moderation when I signed up and it took a little bit before I had full site access. So I will provide the details up to this point and keep you guys updated from here.

The kart is a Carter (I assume based on seat) with a 6hp Tecumseh and one wheel peel centrifugal clutch. We got it from a neighbor for free and it just needed some air in the tires, clutch replacement, toe adjustment, & fresh fuel.
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The single tire drive was real rough on my lawn and the centrifugal clutch was pretty gutless. So I came up with a plan to convert to live axle, add a TAV2, hydraulic brake, shiny DWT wheels w turf tires, & improve the steering. I also have a remote shutoff that will be going on. All the axle parts, hubs, & wheels came from BMI karts.
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  #2  
Old 08-16-2019, 01:49 PM
Smerft85 Smerft85 is offline
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When you say remote shut off, do you mean a wireless control on a fob or something along those lines? If so I'd love to know where to get a few of them!
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Old 08-16-2019, 04:54 PM
Forker45 Forker45 is offline
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Yes sir it’s in the pile of parts from BMI. To be honest it’s overpieced for what it is but just for the pure ease of not having to put it together myself I bit the bullet.
https://www.bmikarts.com/Remote-Engi...es_p_1219.html
The version I got comes with a battery pack for use on vehicles with no battery (most go karts)
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Old 08-16-2019, 05:03 PM
Smerft85 Smerft85 is offline
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Thank you! $80 is good piece of mind when my daughters can reach the pedals and drive on their own, I can cruise behind them on mine and still have some control, that is awesome, I was just wondering if something like this existed.
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Old 08-16-2019, 08:37 PM
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Quote:
Originally Posted by Smerft85 View Post
...I was just wondering if something like this existed.
On the amusement park concession karts, the operator can shut down one or all karts for whatever reason, rambunctious behavior, a collision/caution or what have you.


To the OP:
Along with a remote shut-off (a good idea), make sure you have a driver-operated kill switch, the importance of which cannot be overstated.

Throttle cables can break or bind and leave the throttle butterfly stuck in the wide-open position, the throttle return spring can break or a host of other mishaps can occur and you'll have a runaway kart and a frightened operator behind the wheel.
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Old 08-16-2019, 08:40 PM
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The wheels I picked are DWT 6x6.5” w/ 2.5” offset and the tires are Carlisle Turf Tires 15x6x6. I mounted them up and had to do a little ratchet strap trick to get them to seat but they turned out great.
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The axle is a 1” Flexpruf 40” wide with snap ring ends.
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I back-halved the kart and built a subframe to make it easy to mount the new engine plate and axle brackets.
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Old 08-16-2019, 08:51 PM
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Quote:
Originally Posted by Hellion View Post
Along with a remote shut-off (a good idea), make sure you have a driver-operated kill switch, the importance of which cannot be overstated.
.
There’s a toggle mounted to the steering column

The brake setup is an atv rear master cylinder and the caliper is a left front Rhino 660 utv caliper (twin piston ). Both were cheap new parts from eBay and they’re connected with a braided stainless line. The stopping performance vs the old band brake is no comparison. Haha
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That’s everything up to this point. This weekend I will be tying in the roll bar mounts from the old rear into this new section. I’ll also modify the spindles to change them to 5/8” spindle bolts to run the kart hubs. I’ll also be adjusting the Ackerman to improve the steering.
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  #8  
Old 08-18-2019, 07:32 PM
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Today I removed the old stepped spindle bolts and welded on some 5/8 x 6” bolts. I tied off a string to the center of the rear axle and measured the angle to find the correct Ackerman angle.
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I also moved the bolt down about an inch on the spindle bushing to account for some of the “lift” from how the axle tabs were welded on the rear frame. There’s still a little bit of rake but with the added width of both front and rear the kart should still be stable. I need to get some longer tie rods or extend the existing ones because I don’t have enough adjustment to correct the toe setting right now.
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We did a quick rip in the back yard and the steering is now way better since there’s more steering angle and the tires aren’t “scrubbing” from incorrect Ackerman.
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  #9  
Old 08-19-2019, 04:10 AM
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Looking good
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Old 08-25-2019, 11:25 AM
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Waiting on parts to show up, so I'll do a quick pre-work update.

The previous setup had about the same but was toward center...makes me think they were probably originally designed for use on a trailing spindle setup. The inward angle of the setup caused the arm to hit the spindle mount and limit steering angle severely.

It's hard to see from the photo perspective, but there's about a full 1.25" toe-in. This is from the combination of the added track width and the 12 degrees added on each spindle arm when I welded on the new longer 5/8" bolts. Fortunately the added width (2x 5/8x1" spacers per side) allowed the outward angle to correct the Ackerman on the leading spindle arms.
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I already need to extend the steering links, so I decided to cross them over on the steering mount. This will help even more with the little bit of inside tire scrub we were still getting at full lock. The links are a L/R threaded M8 and the left hand thread just happened to be in the middle. I'll flip them around and will use the right hand end at the steering mount. I purchased some female M8 rod ends and with the right spacers I should have this steering squared away by end of today.
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Sorry for the picture angle off, the forum upload doesn't seem to recognize the phone rotate tag or something...
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Old 08-25-2019, 07:45 PM
Forker45 Forker45 is offline
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Rather than cutting up the tie rods and welding in extensions I used threaded sleeves and all thread to extend the connection to the rod ends.
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The turning radius is now very easily within the width of our road where as before it was about 1.5x if that makes sense. It made running up and down the street a chore and my son wasn’t comfortable driving it.
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Also the steering is much smoother from the rod ends plus I added a 5/8” bronze washer on top of the spindle since it doesn’t have an internal bushing. The only slight negative is it’s a little more reactive/twitchy than I’d like just off center. I’m sure this is due to the straight up caster angle and I’ll probably just leave it be unless it becomes an issue.

Now I’ll add some steering stops and tie in the old rear roll bar mounts to the subframe. Should be pretty much wrapped up at that point.
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  #12  
Old 08-26-2019, 06:30 AM
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You did this old carter good bro it looks amazing when can i have it?
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Old 08-26-2019, 11:45 AM
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You did this old carter good bro it looks amazing when can i have it?
Haha sorry man my son wouldn’t go for that! He’s in love with it.
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Old 08-26-2019, 01:19 PM
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Haha i was just kidding it has a ticumseh why would i want it besides how AWESOME it really is
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