Mini monster truck rebuild

[Possom Point]

I drilled out these Manco spindles to “retrofit” them to this frame as well

 

[Hellion]

Great updates to this magnificent build thread.

What’s the new spindle inner ID?

I wonder if the spindles were drilled out after the Zerk fitting was tapped and added (*at the factory). That has been bugging me with an ‘analysis paralysis’ on Zerk thread length, how to get the inner portion to have zero interference with the kingpin/spindle bolt or having the threaded end of the Zerk with the proper concavity…. I consider greased spindles a necessity.

 

[Possom Point]

Great updates to this magnificent build thread.

What’s the new spindle inner ID?

I wonder if the spindles were drilled out after the Zerk fitting was tapped and added (*at the factory). That has been bugging me with an ‘analysis paralysis’ on Zerk thread length, how to get the inner portion to have zero interference with the kingpin/spindle bolt or having the threaded end of the Zerk with the proper concavity…. I consider greased spindles a necessity.

So the spindles on the go kart truck were 5/8” and on the Manco they were 1/2”, I drilled the manco’s out to 5/8” to fit up to the truck and being able to use 4x4 spindles.

 

[panchothedog]

Great looking work. Bet it's going to come out nice when you're all through.

 

[Felineman]

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[Possom Point]

Some more progress, not guna lie I have several SEVERAL hours making these brackets for the gearbox , made 2 prototypes and made the finished ones, then had to remake them again because the holes didn’t line up correctly. There still not 100% but this IS a go kart so what I have will have to work, also I made slider brackets to be able to tension the chain. So I made the brackets to raise up the gearbox about 1/2-3/4” from the bottom, that way I can get a somewhat flat bottom to have things easier to square, level and line everything up. (Trying to get things straight before welding and paint) Everything is in the prep work!!!!!
Next part will be raising the motor an inch to have clearance for chain so I don’t carve a hole in the side cover.

 

[Hellion]

The bracket material looks really nice and 'factory'. How did you make it?
By the way, is that a drain bolt for the gearbox above the "down" (*3rd pic)?

 

[Possom Point]

The bracket material looks really nice and 'factory'. How did you make it?
By the way, is that a drain bolt for the gearbox above the "down" (*3rd pic)?

It’s 1/4” steel I cut on a laser . Trying to make thing look good along the way.

Yes it is

 

[Possom Point]

New motor mount with 1” riser, I did a 1/4” rise angularly from back to front. So 1.375 on the front end and 1.625” on the rear.
Doing this will hopefully give me the clearance I need for the chain.

 

[Possom Point]

So I cheated the system a little bit with my alignment issue, on the driven I drilled the hole out so that it would slide over the larger diameter of the shaft in the gearbox so it would slide about 3/8”-1/2” closer to the gearbox and moved my motor mount toward the larger sprocket a 1/4”. Took some time figuring but I think got the best alignment possible for this particular setup. Also I got a new tool!!!! Yeah cool tools. Got a pipe notcher and used it for the brace for the sides of the inner body, I did run into another issue but I think I came up with a good idea to make a coupling to connect the throttle and brake rods. I have still not figured out how they did the throttle and brake rod assembly for this truck, how were they able to take the rods out/off???????

 

[Possom Point]

Figured the throttle/brake rods out, I needed to disconnect them from the pedals and then push them up and slide them out of the hole in the bracket, so I will get these cleaned up while everything is apart.
Also I added a brace on the side tubes to help strengthen the frame.

 

[Possom Point]

Made a battery pan with some hooks and a voltage regulator bracket , then wire wheeled and a lightly sandblasted the frame. Will be ready for primer tomorrow night. Got the heat on in the shop to keep any humidity out (hopefully).

 

[Possom Point]

Quick update. I got the frame primed a couple weeks ago, and has been sitting on the back burner for a bit. Had some welding jobs come up that needed to get done. After going through some parts, I had forgotten that I needed to weld a couple things on the frame so I will have to go back and do that soon. I spent today sandblasting and powder coating parts, to get ready for assembly later on.

 

[Grizzlymi]

Can't wait for the reassembly updates! Nice work my man.

 

[Possom Point]

Finally got some work done today, me and the boy out duel coils on the motor, hopefully will be enough for what we plan to do with it.
made the shifter bracket and cut another tube to support it, I decided to bolt the bracket to the tube so I can remove it down the road if need be, plus i would’ve had to cut a large rectangle instead of the slot that I did, kinda did some on the go thinking for this, like I said before, I want to be able to take things apart and work on it when the time comes (maintenance/replacement parts). I also decided to spray paint some of the washers and spring, and the brake band rods, powder coating these didn’t seem fit for what they were plus I didn’t want the heat to mess up the springs.

 

[Grizzlymi]

Nice work and smart planning for the future to make things easier for maintenance and repairs. Work smarter not harder!

 

[Possom Point]

Nice work and smart planning for the future to make things easier for maintenance and repairs. Work smarter not harder!

This was a very different build for me, most karts or mini bikes you can take apart and work on, this one has not been that way, I guess it was a custom type kart but not being able to take things apart to change or fix sucks.

 

[Possom Point]

Re-did the bumpers, the yellow and raw metal ones were way to heavy, found some 2” tube that was about 14ga thick, im not a pipe guy, even with the pipe notcher I bought, so it doesn’t look as good because of the serious gaps I had to fill in, but again it’s a go kart, I’ll just cover it with some paint 🫣🫣🫣

I made some brackets with oblong holes at work for adjustability to get things level, marked and drilled the holes and welded the brackets to the bumpers. I ordered some more lights for the front bumper, and waiting for them to come it to mount the tab locations.
I Plan to start doing the body work soon, when we get some not ICE COLD weather, but spring is around the corner so hoping for some good warmer days to come.

 

[Grizzlymi]

Going to be a balmy 41 degrees around here tomorrow. Hasn't been above freezing in over a month with lows around 0 degrees also. Can't wait for spring!

 

[Possom Point]

Welded the tabs for the lights on and did a little bit of rough sanding, the guy I got the kart from painted all over the old decals, kinda cool there coming to light now, this would have been sooooo cool had it still been 100% together and not busted all up.