2019 - New GrandDaddy build (contd 2018)

[pa17315]

2019 Front and Rear mud/guards painted

This is how it looks. I have waited a long time to see the final results. There are times I am even sure that it would look right or even work out as I have hoped.

 

[pa17315]

2019 Update

Couple of things I will work on next to finish this mud/guard series.

Metal plate on the rear mudguard

Finish putting Herculiner on running boards

 

[pa17315]

2019 Running boards part 2

Preparing running boards for Herculiner application. Existing gray protective layer on metal is very hard to take off. 60 grids sander flap, and paint grinder wheel did not take it off. I have ended up using metal grinder disc to scuff the metal surface.

 

[pa17315]

2019 Running boards part 3

Applied herculiner on running board (2) days ago. It is still tacky. The weather has hovered around high 20 degree to 40 degree Fahrenheit during the last few days. I have started to think about wiring signal lights in the mean time.

 

[landuse]

This is going to look badass when done

 

[pa17315]

2019 Floor steel plate

Prepared and applied Herculiner on the floor plate, pedals and carrier

 

[pa17315]

2019 Propane heater for cold weather.

After looking around to find an alternative solution to heat the work area in the garage, I have settled on Dewalt propane heater. This baby puts out a lot of heat from 27,000 to 68,000 BTU. Other options from kerosene, to radiating units atop of propane tank did not appeal to me. They were either fire hazards or too much fume.

 

[pa17315]

2019 Turn Signals part 1

Here is the diagram for the turn signal that I have chosen for my go kart.

Originally, I was using 7 pins on-off-on switch in place of go kart signal switch. However, for my go kart, it is better suited for a switch. Along the way, I have misplaced the switch and bought new one from Amazon. Unintentionally, it has only 4 pins. That would also work and it would be easier to wire.

On my go kart, two front and rear signals. Additional side turn signals to provide reference for the driver.

Signal switch mounted on main control area. Other options were considered such as on steering wheel, on the side.

On the steering wheel, it is too cumbersome and I have to deal with wires when taking the wheel on and off.

On the side mount where is it easily accessible to the driver would also become another obstacle when getting in and out of the go-kart.

Eventually, mounting on the main control is out of the way and it is only to be used when I turn on the road.

 

[pa17315]

2019 Turn Signals part 2

Lights signals are mounted. 4 inches front amber signal lights and 8 inches rear red signal lights are mounted. Additional bullet shaped light signals for front and rear are mounted under the side mirrors for the front and on roll cage frame for the rear. These bullet shaped amber signals have blue LED lights in the back of the units that turn on when activated.

 

[pa17315]

2019 brake light part 1

Brake light connection is mounted on the roll cage. It is connected from the battery to hydraulic brake switch. Every time the brake is applied, the light would turn on.

Eventually, I would like to connected onto the emergency brake lever as well. I haven't done any research yet.

 

[pa17315]

2019 brake light part 2

I did some research today where brake light is activated by brake pedal or emergency brake lever.

The issue is how to prevent current flowback since you have two switches. Sometime back I have to build an remotely operated chicken door with diode and switches. There are two shut off switch at full opening and at closing. To prevent and separate DC current, a diode was used.

This is basically the same concept so I have sketched up a wire connection diagram. In theory, when I step on the brake pedal, the light would come on. With additional diodes at each switch, the DC current is only going in one direction.

I will test this out to see if it works.

 

[pa17315]

2019 brake light part 3

I have checked my emergency brake lever and setup is different. On my lever, the switch is controlling the ground.

Here is an update pic. Hopefully, I can test it out before final connection.

 

[pa17315]

2019 Go-kart turn signal wirings completed

All signal lights worked

Video to be upload soon.

https://www.youtube.com/watch?v=A1pHlJ9dpR4&feature=youtu.be

 

[pa17315]

2019 Go-kart completion

I hope this is done!

 

[landuse]

Dang it looks awesome!!!!!

Well done! Have you ridden it much now?

 

[pa17315]

Dang it looks awesome!!!!!

Well done! Have you ridden it much now?

Thanks, It is looking nice.

I took it for a drive the other day and something else come up. The brake pedal is so stiff, it doesn't plunge as far as I can press it. I have taken it apart to look at it.

I will post when I have figured out the problem.

Darn, I thought I was.....done!!!!!

 

[pa17315]

2019 Hydraulic brake master cylinder part 1

I have a problem with the master cylinder. Initially, I have purchased a brake kit from Ebay. It has rear and front brake calipers and a master cylinder.

I did not use the front brake so I have capped the port 1 and 2 on the master cylinder. Port 3 was routed to the rear brake caliper. Plunger rods for right and left port was used and connected to the brake pedal.

Since both plunger was used and port 1 and 2 was capped, pressure as build up over time until I cannot press the plunger any further.

I have removed the master cylinder and remove the bolts on port 1 and 2. Sure enough, I can press the plunger again.


Next problem is figure out which plunger port, the right or left activate the hydraulic pressure switch.

Here is the break down:

Right plunger port services Hydraulic pressure switch and port 1. On the picture post below with wire sticking out

Left plunger port services port 2 and 3

I am going to cap port 2 and 3, use only one plunger for right plunger port and see if it works.

There is an alternative that I am also pursuing.

 

[pa17315]

2019 Hydraulic brake master cylinder part 2

There is an alternative for master cylinder. My brother has used motorcycle brake hydraulic cylinder for his go kart. There are advantages such as cost and easy to purchase on Amazon or Ebay.

I bought mine from Amazon for about 14 bucks and another 8 for the hydraulic brake switch.

 

[pa17315]

2019 Hydraulic brake master cylinder part 3

Some pics of the new master cylinder on my go kart.

Fabrication next

 

[pa17315]

Spoindle

Does anyone know where I can get this part? and what is it called?

Thanks