about to start building my first go cart, need help

[suzukigs550]

hey, i have just aquired a 86' suzuki gs 550 streetbike with a good motor and i was going to build a go cart out of it. It has a 6 speed i think which i am going to use. i have a couple of questions though. i want to use the disc brakes but how do i set up a hydraulic brake system that works with petals instead of hand brakes. second, i want to use a solid axle in the rear but what keeps it from moving side to side. third, what thickness axle should i use. with the jet kit for the carborator i should be pumping out about 50-60 hp. if there is anyone out there who has done this before, i would appreciate the help or a couple or pics. i want it a two seater so i can scare the heck out of my friends. any other suggestions would be great also, thanks

 

[modelengineer]

2007 GS500, straight pipes, UNI pods, and rejet carby. Hoping for 50-55hp...

To use the disc brakes you just disassemble the rear master cylinder from the pedal, and attach it to your kart pedal.

On mine the axle is kept from sliding by two keyways either side of the bearings. The keys in the keyways are a specific length so that the axle can't slide. The hubs for the sprocket and brake disc stop the keys from falling out.

 

[Kaptain Krunch]

Heres the one im currently working on, using a 400 twin, not as much power as yours but it should be plenty. http://www.diygokarts.com/vb/showthread.php?t=5055

Setting up the brakes could be as easy as getting some more brake line, and extending the hand brake down where your feet are so you can just press it with your foot. or if your like me and want a pedal you can either use a master cylinder from a car, and attach that to your pedal, or you could just run a cable or rod from the original motorcycle master cylinder to your pedal (would have to attach rod or cable to the handle part). Sorry if that makes no sense, tomorrow i will hopefully finish a little adapter piece im making for my motorcycle master cylinder, and i will put that up on my thread so stay tuned.

To keep your axle from sliding you can either use locking collars (the split kind are better than the ones with set screws), or you can use a spacer made of tube between your tire and axle bearing. I would use a spacer, just because its a little stronger. As for thickness, i would say around 1 1/4" depending on kart size. Mine will use a 1" axle because i already have it, but if that bends i will definitely step it up a size.

 

[suzukigs550]

thanks guys, i think im going with 1 1/4 axle and i had forgotten all about the foot brake. hahaha. thanks alot. modelengineer, that is a sweet looking cart, how long did it take you and is it drivable yet? it looks pretty awesome. thanks guys. that's all the questions i got for now but im sure i will have more later. haha