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The VW bus is a T2. The Bug and Ghia are Type 1. What an awesome build! Wish I had the metal fab skills the OP does.

A swap meet vendor at the Sac Bugorama had one of the Manx bodies for sale so I got to inspect it. Very well made, smooth glass!

Some VW bodies made in southern CA. Bug body http://www.thesamba.com/vw/classifieds/detail.php?id=640925 Manx buggy body http://www.thesamba.com/vw/classifieds/detail.php?id=1484554

I had the same problem. I needed to slide the engine tward the seat to tighten the chain but it hit the seat. I ended up making shims to move the engine up instead of back to gain clearance.

Holly huge pictures, Batman!!

Yes, that bolt size but I used a 1" length. Seemed to work.

Thanks to all the help from this forum, I got it going this afternoon. Daughter is having a blast already. I even took it around the block once. A few adjustments needed, but pretty solid ride. I have another kart similar to this one to do now. Will be much easier I'm sure.

Nowhere to get a half link around here (which would have been perfect, btw) so I made spacers out of 3/16" flat steel. Worked fine, chain is tight. My daughter drove the kart for the first time tonight in a parking lot. Never been on one before and was a little afraid of it at first, but she...

No set screws in it at all. I actually got the kart going today and after a 1/2 hr of use it hadn't moved, so I guess it's fine as is.

Was at the Redding, CA drag strip last night and saw this parked behind the bleachers. Anyone here ever build anything like it. It was pretty crude but functional. I saw it cruising around later on but didn't get a chance to talk to the guy because I was busy in the pits. Pretty cool, though.

I have a brand new chain that I haven't made the on length yet. Exactly how does a half link work, anyway. Never heard that term.

Will do. Thanks.

Look at the pic. Guess which way the engine needs to slide to tighten a chain. Now what, move the seat frame? Sorry for my noobness.

Pic 2

This is what I came up with. I'll zip tie the sheath the the kart frame.

Do I need a spacer behind my clutch? The clutch is flush with end of the shaft, but there is a bunch of space behind it that the clutch could slip to. Do I put a spacer or washers or something back there to keep it from sliding back? After looking at the pic, it looks like the brake drum is...

Wow, didnt know such a thing even existed. Now i know what all the noobs feel like on the model airplane and VW forums I frequent. I'll get some of those nylon ones. They look like just the ticket. Thanks.

Ha! Tonight I discovered exactly everything you described. After getting a cable installed, the engine is not going all the way back to idle due to that long gap from the throttle arm to cable sheath and the weak engine throttle return spring. I'm looking for a place on the engine to put another...

Ok, got it. Maybe iil try something like a 66t. My 10 yr old daughter will be driving this one so no too much weight there. The other one is a little heavier and will have an adult driver so I stay with a bigger sprocket, like the 72.

How small could I go on the sprocket before the the clutch begins to gripe about it? The tires are about 11"-11.5".