Second build, budget kart with curves!

[souperman000]

I was really surprised at how fast this build came together for you. I am interested in how well teh HF tube bender is holding up for you, may I ask how much you payed? I know its on sale right now for $100. Also, did the new heavy duty front wheels hold up well? the reviews on the HF website said they worked good for go karts and things...looking to use them on my kart

[mysteryboy28]

Thanks, this being my second build I am really getting familiar with the tools and techniques, so things go pretty quickly. I have had to redo a few things, which is time consuming. Blah.

The "heavy duty" 13 inch wheels from HF are holding up great, and I've really given them a run for their money with my fat a$$ taking them out on the trails. Lol.

The tube bender works good too - but be sure to pack the tubes tight full of dry sand (duct tape one side, fill it half-way, pound it in good with a steel rod or something, repeat till completely full and really packed good!) to prevent crimping of the tubing/pipe. I tried it both ways, packed, and unpacked - and it REALLY makes a difference! For major bends you're still going to get a little crimping even with sand, but it'll be tolerable. I paid about $84 out the door with the 20% off coupon. The toughest part about using the tube bender is guestimating where to make your bends so everything lines up perfect. Measure and mark the tubing and the die so you know where you're supposed to be. Often times I will bend a tube to ALMOST where I want it, take it out, measure and compare, and then put it back in the bender for a tad bit more bending.

[mysteryboy28]

Got the brakes installed, working pretty good - for mechanical brakes. I got spoiled with the hydraulic brake on the big kart, especially once I got that dialed in perfect.

Meanwhile, I need to loosen the chain a bit, it's really pulling on the centrifugal clutch, causing some unwanted rubbing (didn't know there could be such a thing, lol). I was trying to get away with just drilling 4 mounting holes for the motor, so that I wouldn't have to deal with "engine creep" causing the chain to get loose. But looks like I'm going to have to make the little tracks for the bolts so that I can adjust the motor a bit. Blah.

Had my girlfriend take the kart for a spin and she said it handled great and was FAST. Yay! Lol. Bought some black vinyl for making the seat cushions. Actually found a couch cushion out on the abandoned golf course, in good condition, which will save me a few bucks. Now just need to find another cushion for the back rest. Jo-Ann Fabrics wanted like $14 for a 24" x 24" x 2" piece of foam. I told them where they could stick it. Not really.

[mysteryboy28]

Some pre-paint pics for ya.

[rcarteraz07]

Looking pretty good! Keep it up!

[flowerman]

Love it... The style is a little like a manco dingo 285

[mysteryboy28]

Post paint, mid assembly. Couple of adjustments need to be made, like the tracks for the 4 engine mounting bolts. Still looking for padding foam for the seat back.

[mysteryboy28]

Finally the mini-kart with curves is complete! I'll give it a wipe-down and take some better pics during the daytime.

Ended up getting the foam at Jo-Ann fabrics. Turned out it was on sale for half off this week! I decided to replace the 3" thick couch cushion foam with 2" thick high density foam since it was a lot cheaper than I thought it would be. Used 1" thick high density foam for the back rest. That made a world of difference by taking most of the vibration out of leaning back! My brain doesn't rattle when I ride anymore! Yay!

Also, I GPS'd the kart on a nice open stretch of road and hit 40 mph! That's pretty scary in that little kart. Lol. Yee-haw!

[rcarteraz07]

It looks amazing! Good job man!!

[souperman000]

again, I am surprised on how fast this ting came together, looks good too.

May I ask about how long your little axle stubs (not sure technical names) are for your 13" heavy duty tires? I purchased some and my axle is just too short for them to fit with the double hub. Thanks

[mysteryboy28]

I think they are just 4 inch bolts (5/8") that I welded onto 1 inch tubing, along with some angle iron for pitman arms to make my spindles.

take a wheel (or the hub) up to the hardware store and try a few bolts to see what size goes all the way through with plenty of room for washers and locking nut. then when you get home saw off the old "stub", grind the surface to accomodate the bolt (some bolts have numbers/letters on the end of them that you'll want to grind smooth), and weld them on the best you can. Keep in mind that zinc is toxic when burned, so make sure you're in a well ventilated work area and try not to breathe the fumes.

Hope that helps! I actually busted the wheel bolt (little axle stub as you call it, not sure of the exact term as it's part of the spindle) and pitman arm off the big kart on sunday by running the wheel right into a boulder. Oops! Easy fix though, and stronger than ever because the welder I have now penetrates much better than the one I originally made that kart with. I've had to fix several welds! Luckily nothing has broken that was life threatening... yet. Lol.

[landuse]

I think it is called the kingpin bolt. Not 100% sure though.

Brilliant build!! Well done

[mysteryboy28]

The kingpin bolt is the vertical bolt that the spindle pivots from. I like "wheel bolt", but
I realize that not everyone has a bolt welded to their spindles like I do.

[mysteryboy28]

Final pics are here! Yay! Lol.

[exenos]

Looks like it'll fetch a pretty penny if you decide to sell it.

[mysteryboy28]

it's actually up for sale now - $600. the black and green mini-bike is going for $250.

[mysteryboy28]

would like to sell it quickly so i can pay rent and buy supplies for the next kart (already have a brand spanking new 6.5hp motor sitting in the box just waiting...). debating whether or not to throw a roll-cage on it...

also debating on simplifying the front suspension on the big kart to a single A-arm setup, removing the whole front end to make a shorter wheelbase - thus also shaving quite a bit of weight off of it, and improving the turning radius. hmmm...

[souperman000]

I think the roll cage looks good

[mysteryboy28]

Roll cage constructed, paint drying, pics coming soon!

[bighead]

Looks good. Still do not like the steering shaft bolted to only the thin floor pan though. I like the cage in the first pic above. Nice work.