Boy Scout kart build - dubbed "The Hot Rod"

[Bugzuki]

Still curious how you are bending the tubing.

I'll take a picture of the table and post it.

Many years ago we built portable sawmills and made bent bars for that. My father had all the stuff we used to use sitting around, including the big (now) rusty table. On the side of the table is the tube bender we used to use. It is for pipe, but works decent for the DOM tube. It has a hydrolic ram that is driven by an electric motor and a 12v battery. The ram turns the bender and I use a digital level to try and get the correct bend angle.

There is some fudging necessary because the tube springs back when the pressure is released. So, you have to bend it farther than needed then measure when unsprung.

You can kind of see the bender in these pictures:

 

[Bugzuki]

4th of July update

I got some more work done yesterday.

Got the engine remounted. It now allows room for the chain and sprockets.

Here is a shot of the drive pulleys. In their current position they are within a 1/16th of an inch from the 10 1/8th inches that we measured on the sled before we took it appart.

The reverse drive is mounted again with the engine in the new location. I was able to keep the reverse mechanism in the same spot.

Got some work done on the rear knuckles.

The bearing hub will bolt to the plate that is sitting on the table. Then the axle shaft comes up through the hole in the top plate.

Hopefully we can get the rear suspension put together this evening when the scouts are over. That reminds me I need to get some bolts.

 

[bighead]

Coming along very nice. Are you going to have room for the exhuast pipe? I would try to use the original exhaust if you can.

When I built my sled Ody. I had to change the angle of the header. Probably better way to do it. But this is what I did. I just cut the header pip about 98% thru the whole header. (I did not cut it all the way off) Then when it was almost cut off off. I was able to just bend it down to the angle I needed. I then filled in the gap with a exhaust pipe. Not cutting the header all the way off made mock up really easy.

Depending on how close your exhaust comes to your seats. You may also consider a heat shield there.

 

[Bugzuki]

I was going to do something like that. I will probably modify the pipe not the header as I think I have space for the header the way it is. I will have to shorten the straight part of the pipe before the expansion then re-angle the output tube.

It looks like your exhaust was a little easier to work with than mine is. It has a hair pin 180 degree bend right where the expansion starts, and that doesn't fit anywhere.

Thanks for the advise.

 

[bighead]

I have an expansion chamber pipe I would let go pretty cheap. Say $10 plus shipping. It is a 440 sled pipe. I will take some pics. BRB

 

[bighead]

Here is the pipe in question. Some pics of the pipe and the motor it came off of.

As you can see it a small J shape. It fit right in your buggy. I do not see any mounting tabs though. I do not have the silencer tip though. Your buggy would be loud with this pipe. It's small and simple.

it has a very hi ridge seem down it's centers. You could braze some mounts on that pretty easy. Not having to weld on the thin pipe part. Or perhaps your mig welder welds exhuast pipe well. I never had much luck welding old pipe like this. The pipe is solid with no rust holes. I still have to take the wrape off and look under that though. Pretty sure it is a solid pipe.

If you look at the last pic you can see how the pipe hooked to the header and ran right under the motor. The pipe shape would be easy to work with.

After looking at your pics. This pipe would go right under your engine. Keeping the noise low and out from your head. I hate that my Ody's pipe is right by my head. I cannot hear a thing. And that with a big muffler. I can only amagine how loud this would be with no silincer. But if you like loud just run it.

 

[bighead]

To give you a better idea if this pipe will work for you. I posted pic of this hacked up Ody I bought for parts. You can see how the hacker ran the pipe under the engine. And the room it took to do so. I just thought this would give you a better idea.

Note that this engine is mounted two miles up in the air. The header will be lower on your buggy. Also the headers should be about the same distance as far as far as they stick out. Or close anyway.

Let me know.

 

[bighead]

I also have another set up I would sale. Hard to explain so here is some pics. This is also a 340cc sled. This was on another sled Ody I bought. It is well made. The pipe is facing the arong way in some of the pics. I do have both silencers. These would go over the top of your engine point right out back.

It is just a box steel with some Yamaha ATV silencer modded. Easy to make.

I like a expansion chamber the best though.

 

[B man]

To give you a better idea if this pipe will work for you. I posted pic of this hacked up Ody I bought for parts. You can see how the hacker ran the pipe under the engine. And the room it took to do so. I just thought this would give you a better idea.

Note that this engine is mounted two miles up in the air. The header will be lower on your buggy. Also the headers should be about the same distance as far as far as they stick out. Or close anyway.

Let me know.

did you restore this one? is it the 340?

 

[bighead]

did you restore this one? is it the 340?

I still have the Ody. I sold the engine on Ebay for $200 full of sand. I keep the pipe for I thought it was cool. The 340 Ody is behind it in the pics.

Also Bug, I would see if my pipes fits. And then look for a silencer. Kind of like whats on my yellow racer. Here is a pic. Again right by my head and I cannot hear nothing.

Also wondering whats works best when welding on old Pipe like this? Brazing? Mine have always crack when I have tried. Thats why I went with moding the header. Notice the hand made pipe in the pics? You got the skills make one of those.

Not sure if you leaning this way or not. Just thought I would give you some options. I am sure it will be sweet no matter which way you go.

 

[Bugzuki]

Cool thanks for all the ideas bighead. I was thinking I would have the exhaust go across in front of the engine and then turn back and have the silencer above the reverse drive. There is a silencer at the local motorcycle shop for 75 bucks (some "Power Turbine" or something like that). I was thinking I could probably get that.

Where are you located. I am in Monroe and work in Bothell.

I think for the flanges I would buff some of the rust off and try to TIG weld them on.

I might be interested in one of your expansion chambers. I'll send you a PM.

 

[Bugzuki]

I still have the Ody. I sold the engine on Ebay for $200 full of sand. I keep the pipe for I thought it was cool. The 340 Ody is behind it in the pics.

Also Bug, I would see if my pipes fits. And then look for a silencer. Kind of like whats on my yellow racer. Here is a pic. Again right by my head and I cannot hear nothing.

Also wondering whats works best when welding on old Pipe like this? Brazing? Mine have always crack when I have tried. Thats why I went with moding the header. Notice the hand made pipe in the pics? You got the skills make one of those.

Not sure if you leaning this way or not. Just thought I would give you some options. I am sure it will be sweet no matter which way you go.

In your yellow kart do you have a pump or something in the gas tank to feed the engine. I am debating where to put the tank on my kart. Up front would have space, but don't know how to get the fuel to the back. In back it would probably sit high, so I might not need a pump.

 

[bighead]

I am in Portland. So shipping will be pretty cheap.

 

[Bugzuki]

Made some progress on the rear

We were hoping to have a roller last night, but took too long.

We got the rear suspension together a bunch.

I hope to get some more done on it soon. The count down is on.

 

[Bugzuki]

Rolling Chassis - Major Milestone

Well, last night I put it together and tacked the shocks on.

We pushed it up and down the street, over the curbs and stuff. It drives a lot straighter than I was thinking it would. It was really stable over the curbs and did not seem to jump around or have noticable bump steer.

The rear springs are definitely not strong enough to work in a direct loading configuration - like I put them. I need to do a rod/lever setup I think.

Well, here are some pictures for your viewing pleasure.

I am so excited. My list of things to do is getting smaller:

1. Rear Axle
2. Drive Sprockets and Chain
3. Exhaust
4. Floor
5. Gas Pedal
6. Brake Pedal
7. Brake Lines
8. Gas Tank
9. Wiring
10. Lights
11. Paint
12. Licensing

Not necessarily in that order.

 

[Bugzuki]

I weighed the kart this morning. My scale is limited to 400 lbs, so I had to do each wheel individually. The weights came out like this:

Left Front: 115 Right Front: 113

Front: 228

Total: 578

Rear: 350

Left Rear: 179 Right Rear: 171

I am figuring this is an approximate weight but should be pretty close to actual. I am hoping that the final weight will be around 650, hopefully not as high as 700lbs.

 

[bighead]

Looking great. What paint are you going with? Will it have a Scout theme? I love the wide stance. This should be a stable buggy.

Be prepared right? What add on's will you being doing if any? In my State of Oregon you are required to carry a shovel on buggies during fire season. Not sure of your state though. But this is what I did. It also derects are into the fan.

Forgot to call you on that pipe. If you need any of them let me know. There are not going any place fast.

 

[redsox985]

I don't quite understand why you need a shovel in fire season, I'd think a small extinguisher would make more sense, but read up on all rules before finalizing the kart. Just so you don't step back, smile, test it, and find out you have to take off that paint job and change something.

 

[Gear box]

I have to say that looks sweet, very good job I like what you've done.. Keep up the good work.

Hers to the BSA!!!!

 

[bighead]

I don't quite understand why you need a shovel in fire season, I'd think a small extinguisher would make more sense, but read up on all rules before finalizing the kart. Just so you don't step back, smile, test it, and find out you have to take off that paint job and change something.

It helps makes the tree huggers happy in Oregon. Wild fire is a huge deal in Oregon & Washington.