dnuccio's build thread

[dnuccio]

hello everybody! im new to the forum, not very new to karts though. this will be the build thread for my 3rd kart.

first ill give you a little background about me. my name is daniel, and i live in phoenix, az. im 16 years old and just recently got my license. i have a 95 jeep grand cherokee, which has been my baby. ive got the jeep pretty much to where i want it, so now im going to start the build up of my off roader kart. the building will not really start until i land a job, hopefully within the next week.

this was my first go kart. i got it when i was 12. i learned to weld and had some fun with it. dont really know why i sold it, but i did.

http://i1247.photobucket.com/albums...95Y15T55Q4b1jf1d1c24feae4131c_zpsac9b9516.jpg

this was my 2nd go kart. got it last summer for $40. it had a 3 horse briggs on it, which i got running and traded for a briggs raptor engine.

http://i1247.photobucket.com/albums/gg632/dannuccio/Go Karts/WP_000100_zps27a243a9.jpg

http://i1247.photobucket.com/albums/gg632/dannuccio/Go Karts/WP_000098_zps806a572f.jpg


and here is my current kart, given to me by my grandpa.

http://i1247.photobucket.com/albums/gg632/dannuccio/Go Karts/WP_0012092_zps8809b708.jpg

it had a 5 horse OHC honda motor on it, but that wont be enough for what i have planned...

 

[OzFab]

it had a 5 horse OHC honda motor on it, but that wont be enough for what i have planned...

Why, what do you have planned? I have a mildly worked GX160 on my kart & it flies without really trying...

 

[dnuccio]

Why, what do you have planned? I have a mildly worked GX160 on my kart & it flies without really trying...

it may not look like it, but that frame is VERY heavy. and its only going to get heavier with what im adding. this is going to be an off road toy so i can go out riding with my friend (he has a manco dingo). i plan on putting some big 16x8 tires on it and possibly making a suspension in the front. plus im a pretty big guy (around 5'11" 240lbs).

im going to use a predator 420cc engine

 

[dnuccio]

does anyone know if they make a 7 inch diameter rim with a 4 on 4 bolt pattern? i want to use these tires
http://www.bmikarts.com/16-x-8-7-Trail-Wolf-Knobby-Tire-_p_1534.html

but i dont want wheels that slide onto the axle, i want to use hubs with wheel studs like a car.

 

[dnuccio]

got some work done to the kart today. stripping it down to nothing basically.
the genius guy that built this thing thought a good way to attach everything to the axle was to weld it! yep, he welded EVERYTHING to the axle. sprocket, wheels, brakes, all of it. see pictures. ended up just cutting the flanges (since im going to use pillow block bearings anyway).


hopefully i uploaded the pictures the right way this time. if not, im sorry.

 

[OzFab]

Pfft, amateurs... Looks like you may have to replace the lot, unless you do some fancy grinding to save, at least, all the hubs (brake & sprocket included).

Personally, I wouldn't trust the axle as it has, effectively, been severely heat treated in several areas; it will now have a tendency to snap...

 

[dnuccio]

Pfft, amateurs... Looks like you may have to replace the lot, unless you do some fancy grinding to save, at least, all the hubs (brake & sprocket included).

Personally, I wouldn't trust the axle as it has, effectively, been severely heat treated in several areas; it will now have a tendency to snap...

i may try to save the brakes, as that would save me around 50 bucks. but other than that, im not saving any of it. im getting a new axle, wheels, tires, sprocket, everything.

 

[dnuccio]

went and picked up some welding wire, so tomorrow i will start on relocating the seat. the metal im using to build the seat frame i trash picked, it was actually an old pool fence, but its got alot of good 3/4" square tube, and a little bit of some bigger square tube.

think i figured out my gearing. i decided not to go with a torque converter to save some money. i will be running a jackshaft setup. the clutch will have a 14 tooth sprocket, driving a 20 tooth on the jackshaft, with a 9 tooth on the jackshaft driving a 54 tooth on the axle. if my math is right, this should give me around 8.5:1 final drive ratio. with 16 inch tires, this should give me reasonable speed with excellent torque.

i am still mostly in the information gathering stage of the build, because i need to get a job before i can start buying parts.

 

[landuse]

From where I am sitting, your gearing plan sounds good.

 

[dnuccio]

got some more done today.

cut up all the tube from that fence piece i trash picked. can you say tetanus?

made some spindles from 3/4 inch square and some 1/8 inch flat stock i had laying around. the ones that were on the cart were backwards (again, a genius built this )

and finally made most of the seat frame. just need to add some braces between the upright bars. probably doesnt need it, it feels very sturdy, but id rather not have it break while im out riding in the desert.

 

[dnuccio]

so i think im going to make the seat a little lower. i think with it where it is now, the COG will be too high, which for an off road kart (or any kart for that matter) is bad. i made the seat high up because i wanted to avoid having to cut and stretch the frame, but at this point, i think im gonna have to do that anyway.

let me bounce an idea off you guys. how do you think a 5 horse OHC honda motor with a torque converter would compare to a 420cc predator with a 8.5:1 final drive ratio thru a jackshaft?

 

[Cole Tallerman]

I think you should do a predator 212cc with a torque converter. That will cost about the same as the 420cc. Torque converters run about $110 on ebay brand new. The 212cc predator with a few modifications will put out more then 7hp and will easily run at 3800 rpms by just removing the governor. This solution is cheaper and will save you engine room and money. Plenty of people run 2 seater off road karts with this engine and they do fine. Also keep in mind that a clutch for the 420cc will run you around $100 because it has a 1" bore.

Edit: look online for a 20% off harbor freight coupon

 

[landuse]

I think you should do a predator 212cc with a torque converter. That will cost about the same as the 420cc. Torque converters run about $110 on ebay brand new. The 212cc predator with a few modifications will put out more then 7hp and will easily run at 3800 rpms by just removing the governor. This solution is cheaper and will save you engine room and money. Plenty of people run 2 seater off road karts with this engine and they do fine. Also keep in mind that a clutch for the 420cc will run you around $100 because it has a 1" bore.

Edit: look online for a 20% off harbor freight coupon

This is probably a good idea...

 

[dnuccio]

yeah i think im gonna go with the 212 predator and build it up a bit. for starters ill remove the governor and get a billet rod and flywheel. next im thinking cam and valve springs. whats a good cam for these things? id like as much low end torque as i can get. any other not super expensive mods i should think about? i built up a 6.5 lifan clone a couple years ago and put it on a mini bike, so im not really "new" to these engines, but its been a little while. before that i was into briggs flatheads, but i love the power potential and gas savings of the OHV clone.

i will run a torque converter, should i use a #35 or #41 chain? i was going to use 41 with the bigger predator, probably not a bad idea with a built up 212 predator.

 

[landuse]

#41 will be fine

 

[dnuccio]

got a harbor freight flyer in the mail yesterday, had a coupon for the 212 predator for $99.99! hopefully i can get some cash together before the coupon expires

 

[dnuccio]

well guys this project will be shelved for a little while. got some stuff i need to do to my jeep, and since its my daily driver, i have to keep up on fixing it.

this thread will not die, the kart will be finished, but it will be a while. stay tuned