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Howdy 🤠 ...& welcome :cornut: Probably, opposite of what you should have done. Usually the "best" place to start when DIY figuring gear ratio, on a small vehicle is ~6:1 ;) For example, a 10 tooth "drive" sprocket on the motor ...& a 60 tooth "driven" sprocket on the axle What is the...

Bottom front sections...popped off of the "plug" mold :wai: Rear sections...too :bannana: Attacked 'em with a garden hose...ta clean 'em up (mainly to wash out any PVA &/or fillet (caulk) residue)

Trimmed up the rough edges Then, flipped 'er back over Drilled out the bolt holes Removed the nuts & bolts ...&/then, popped the rear top section "back off" Re-removed the front top section...too Close up of (1) of the flanges that we created ...& seam/fillet

Hey T, I was/have been kinda intimidated (at first) ...but, once ya "wrap your head around it" ...&/then, do it a few times ...it kinda "grows on ya" :cornut: All of this was required just ta make the mold ...& its a "good size mold" :innocent: ...& needed ta be HEAVY DUTY :cheers2: See why...

After caulking ALL of the "new" seams ta make fillets ...& taping the bolt holes ...I gave the LAST (2) sections a coat of the PVA So far I've used about 1/2 gallon of the PVA on this "plug" mold ...& just by "bagging" the cup & brush, I've been able to use them for this whole project :wai...

Did anyone notice the big 'ol scratch/gouge in this pic? Or the sloppiness of this fillet? Or on this (4) way junction Well...I have found that many minor/superficial "issues" like these, can/will be filled in/covered up by/with the PVA (barrier cream) ...so, in this situation "good enough...

Hey Denny, Yup, I've seen clay fillets used in many videos (a lot of "rolling snakes") ...& folks using wax for making fillets too (more rolling of material) I just figured "shooting" fillet material outta a gun would be quicker & more efficient ...& Latex caulk is really easy to find I was...

Flipped 'er over ta work on the other side More flangette establishers More fillet(s) Closer up(per) view of a curved fillet Closer up(per) view of a junction fillet * I kinda "got ahead of myself" ...& drilled 1/4" holes along the perimeter flanges ...so, I "ran" a strip of packing/box...

Wonderful! :bannana: Tryin' ta inspire others...is (1) of the main reasons that I do alot of this stuff :wai: ...& I really enjoy designin' & makin' & showin' folks how ta do stuff...too :thumbsup: & I really don't need 20+ karts...either :eek: ...but, that's a whole other story ;) Yes...do...

Love following along, heavily illustrated build threads like this...well done :thumbsup: ...& keep up the good work :2guns:

I re-installed the rear/top section of the mold (on the "plug") ...& the front top section...too Drilled some 1/4" holes ...& bolted 'em together (1/4" nuts & bolts) Notice the nice-n-beefy junction :2guns:

Top/front section Closer up(per) view * Used the garden hose, scraper & a brush to wash out any PVA residue Did some "dry" clean up on the "plug" too Mostly scraping off the caulk (seam sealers/fillets)

Lookie what I went & did (de-molded) :thumbsup: The "plug" sustained some "battle damage" (mostly superficial) :ack2: On the "nose" too Close up(per) view

I let 'er cure overnight ...then, used a 1" straight edge ...& a sharpie to "mark" the flanges for trimmin' Then, used the oscillating tool ta do the trimmin' * Notice the vacuum hose? (hanging just above the trimmin' area) ...& the debris "catch bin"? (down below) This pic shows the...

The first & second layers were only CSM (chopped strand mat) ...but, with the third layer, I started adding in some of the stronger 1708 cloth ...& installed some re-enforcement "ribs" too ;) Fourth layer done (mostly 1708 cloth) :2guns:

Hey T, This is only the first layer on the first section ...we have a long ways to go...my friend :thumbsup: Second layer on first the section Another view I found that ya shouldn't apply the PVA (barrier cream) too far in advance ...'cause (as we have seen) moisture has an effect on it...

After cuttin' some FG cloth ...I started a fiberglassin' the first section :thumbsup: Work "in progress" Side view Wrappin' around the "nose" First layer...done :2guns:

Hey T, I have still been following along on your (& others) projects (with my phone) ...just kinda outta of my "comfort zone" for posting &/or responding ;) So/by the time I got the PVA applied it was gettin' dark ...so, I covered 'er up for the night with one of them blue HF tarps ...but, it...

Been havin' some computer issues ...but, I'ma thinkin', that I'ma "back in business" now ;) Still makin' progress Like makin' flangette establishers Installin' flangette establishers Wrappin' 'em around the "nose" Gonna split the top, into (2) sections Used some Latex caulk to seal up the...

Wanted to "point out" some "body work" detail Like, notice the big 'ole "gap" along where the hood meets the fender "area" ...& where the hood & fender meet-up with the headlight? Well...this is the other side (didn't get any pics of that side) :mad2: Up(per) closer view I think it looks...