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I assume it would turn sharper, but be less stable at speed.

I just did the math, and I should be in that range. The brackets are offset 1/2" horizontally, and they are spaced 4.25" vertically from hole-to-hole. That should give me a caster of 6.71 degrees. Now I just need to do some investigation as to why one side has more caster than the other...

I understand what caster is... I'm just not sure how much caster I should be shooting for. At this point I can dial in as much or as little caster as necessary. Is there a rule of thumb for this? Or should I just make sure both sides are equal and move on? I was thinking of drilling and...

Interesting... mine seem pretty tight, although I haven't put them under any stress yet. Where did you get your from?

You are correct. The upper attachment brackets are set 1/2" further back than the bottom brackets. Something is slightly off though, because when I put on the spindles, the left one is angled a just a little steeper than the right. It's not catastrophic, but if you stare at it, you can...

A few issues that presented themselves today: 1. The suspension block itself appears to have twisted a little while tack welding. It's visually apparent, but when I took measurements with a digital micrometer, I'm finding outages in the .020 range, which I'm surprised I could actually see...

Got the front suspension blocked tacked together today. Now it gets interesting :ack2:

Yeah, all of those parts are from BMI Karts.

Progress! A-Arms built today. Building the jig was more time consuming than actually tacking the parts together, but I think it was worth it. They came out pretty uniform.

That's an excellent idea. Does anyone make splined shafts like that? I know shafts are sized by diameter and number of splines. Are they manufacturer specific, or is there a standard? In other words, if I had a Honda engine, would I have to go to Honda for a shaft to fit the kick start...

Still undecided on the motor. If I go for a dirt bike motor, I know how to make the shift linkage work, and I think I have enough room at the front end to run a foot clutch. I still would need to figure out some sort of starter. I haven't had any luck with that so far, although I have to...

45" http://www.bmikarts.com/shop/?shop=1&cat=259 Near the bottom. Item #601845.

I don't see why not. 1" appears to be a very common size judging from the parts available from the vendors I've been buying from.

1-1/4".

New Parts Today Got parts today. Waiting on bushings to come in for A-arms, and I'll start assembly on the front suspension, hopefully this weekend.

I've done some searching this afternoon on Craigslist and Ebay, and found surprisingly few potential donor machines so far. Admittedly, it's been awhile since I browsed the used dirt bike ads, so maybe I'm out of touch. But I think some people must have lost their minds for what they're asking...

Outstanding! That's just the thing for the shifter. Now if I can learn how to mate an electric starter motor to the kickstart shaft, the dirt bike engine becomes a very attractive option.

That's kinda what I was thinking, although the dirt bike / quad engine route presents a couple issues: 1. Need to find one with an electric start, or easy to convert to electric start. Given the rear swingarm frame design, I'm not sure there is clearance for a kickstart lever to make it's...

I'm considering the 10hp horizontal Tecumseh recommended in the plans, but there's a part of me that wants to pick up a used dirtbike or quad off craigslist and start from there. I like the idea of a manual transmission, and I suspect I could pull it off cheaper than the Tecumseh plus torque...

Front suspension block parts mocked up: