Minor Manco

[Quaddakeric]

Got this cart from my father-in-law about three weeks ago. He originally got it for his now 23 year old son when he was 5 or 6 so yeah, its an old cart. I will be fixing it up for my step-son's 6th birthday in August.

The old B&S was crap. Steering wheel is made of chain and welded to the steering shaft. Tires were hard as a rock and both rear axles are bent a little and one spindle has some grooves wore into the underside of the axle.

You can see I already got a 6.5hp clone. So far I've removed the tires from the wheels, painted the wheels satin black, replaced all bearings, mounted new tires and that's about it. Got a new clutch, chain, band brake and drum and cables coming in sometime next week I bought online. Hope to get it running in the next couple weeks then strip it all down to prep and paint! I'll keep the updates coming with pics.

 

[Blazkowiez]

Being a Manco you will have a hard time with return on the main pedal and governing. Two remedies I've found almost necessary on these karts will be a strong return spring from the pedal and a pedal stop, an adjustable one made from a bolt is much better than a stationary model. This will be very important due to the age of the rider.

 

[Quaddakeric]

Yeah, I plan to do some semi-heavy customizing for him. I thought of possibly shortening the pedal reach from the seat or making some extensions that attach to the pedals. And I will most certainly have a pedal stop.

 

[Blazkowiez]

You can turn Manco pedals around and gain 4" from that process though you'll need to weld a forward stop so they sit flush. There is not much you can do from the seat for extension. I will say this though, if the first adjustment is not enough the child is too small for the kart. Without a 2:1 gear reduction unit on the kart your slowest speed without burning clutches is approx 18mph. Anyone who is not a proper size to control the kart will damage themselves along with the kart very fast.

 

[Quaddakeric]

How would I go about getting a 2:1 gear reduction?

 

[Kaptain Krunch]

You may have to run a jackshaft to get a low enough ratio. Its better to gear it lower than to use a pedal stop and burn the clutch.

 

[Quaddakeric]

Updates!!!

Yeah, its been over a month now. But the old "Minor Manco" is very close to being complete. Right now I've got it together and running safe enough for my son to run circles around our 3/4 acre backyard.

New parts: pedals, tie rod ends, seats, cables, motor, clutch, chain, band brake and drum, springs, tires, nylon lock nuts for spindles and rear axles, seat belt, wheel bearings.

Moved the pedals up so he can reach. Bout to move them 6 inches further away cuz they are a just a little too close and he has problems lifting his foot off each one. And you can see the kill switch semi-permanently attached on the steering support.

Scrub brake removed.

Band brake installed.

Used U-bolts under the seat on each side to attach a seat belt.

Made a solid bench seat with individual bucket backs. One of my favorite touches to the kart right next to....

.....grabber green tank and dust cover on the honda clone!!

Also put a bumper on the front so that he won't nail a tree or any other inanimate object and bend or break a spindle.

I managed to strip off 4 layers of paint!! This thing was originally green, as you can see. It has since been painted white, red, black, and then red again. Its final color is going to be grabber green, which is my son's favorite color. Going to look great with a semi-gloss black front bumper and wheels.

What I have left to do is paint the whole frame, replace steering shaft and wheel, move pedals up a bit and probably put a full length skid plate on the thing.

Oh...and one last pic:

He LOVES this thing. Actually getting pretty brave and tries to make it fishtail on him in the loose dirt out back.

 

[turbojimmy]

He LOVES this thing. Actually getting pretty brave and tries to make it fishtail on him in the loose dirt out back.

Nice work! I'm working on an old Manco for my 9-year-old. Having been bit by the bug, we also put a 6.5 HP clone on a minibike that I rode when I was a kid. It's fun watching him sort it out, and eventually get brave (like you said) with it.

Enjoy!

 

[mrfreyguy]

Just so you know having a seatbelt with no roll cage is extremely dangerous. If the kart was to flip he would be trapped under it. If you don't have a seatbelt and it flips there's more of a chance that he will be able to get away from the cart without injury.

 

[Quaddakeric]

I doubt he could flip it: never gets fast enough and he won't ride it like I would. And if he was to flip it, I would be there to get him out since he always rides under my strict supervision. I'm pretty confident he's safe. Worst injury so far is a blister from the steering wheel and eyes full of dirt.

 

[Blazkowiez]

Any kart can flip over, getting out is not the only problem, think about how dangerous this is... its not a joke and far more dangerous than not riding with one.

 

[redsox985]

I was thinking the same thing as I read through the thread. Any production kart without a cage is also without seat belts.

 

[Quaddakeric]

Green enough for ya?!!

Went around with a wire brush attachment on the drill to clean up some high rust spots and stubborn paint and found out the very first color was yellow. Seems to be the same yellow as this kart, Clint Burleigh's project:

http://www.diygokarts.com/vb/showthread.php?t=8337

Also noticed a tag on the back of the seats with a serial number: 391-8076, and 1263 below it. Is it possible to find out any info on it?

And I've done some hard thinking about a roll bar. I am going to put one on it. Its not going to take a lot of time to do and even if it does, my boy's safety is worth it.

Reassembly will be tomorrow with roll bar construction to follow so....updates soon!

 

[Quaddakeric]

Quick sneak peak at the completed kart...just gave it to him for his birthday today and I haven't had time to take detailed pics but they're comin'.

I have to say...considering what it looked like before(two months ago)....

....I did pretty good friggin' job!

 

[fowler]

if u say he never goes fast enough to roll then a seat belt is a good idea because somone that size their worst chance of indury is going around a corner too fast and sliding off the seat or being bounded off the seat then being draged or run over by the back tyre

but yeah the best bet is to put a roll cage on

 

[Quaddakeric]

Starting work on the rollcage/rollbar this week actually since he won't be riding the kart much, if at all....he's gotten hooked on Super Mario Galaxy 2 and enjoys the co-star mode with me playing Mario so..... ....yeah. Which is still father/son time so its cool.

 

[Blazkowiez]

Dude, I would take the video game thing as a great thing. The kart will be great entertainment till he is 14 most likely and will be a great fit if he seems way too small at the moment, which from a professional standpoint I think he may be too young for that kart.