Why not use a small dia tube or pipe that is 5/16 id., cut the heads of 2 bolts and weld them into the tube, this is much better then a 5/16 rod for a tie rod. Larger dia. less flex.
but i though he ruled that out cause he would need to buy new rod ends, he could buy some threaded rod which would allow him to use his current rod ends on home-made tubular tie-rods, anyway 
Bob,
What is the measurement between your front axle center to back axle center?
Bill

This is the INSIDE MEASUREMENTS I have found comfortable use in buggies, if you are a larger person then the size has to be extended. L 52", W at butt 24", W at feet 14"


I guess it's a good thing I am only 5'9". I will be sure to lay the kart out on the driveway to get MY cozy dimensions.
Thanks for the measurement Grizz, ...

I wish I had stretched my frame by another couple if inches, I can only imagine how cramped the standard frame is. I also think that the foot well area should be a lot wider.
You are ahead of me on the leg room Wobbly, but I have to agree about more foot room. Frame tapers to 10" at the suspension block, would be a lot more comfortable at about 14" I would suspect. That would put it around 16" in the pedal area.Grizz I would cut that frame and extend it 10" at least. I don't think it would be all that big of job. That length will be ok for short runs around the yard, but if you plan on doing any riding then that is way to short.
theo, I have been suspecting that in the back of my mind for some time now, since I first put the seat in place and saw how close the pedals were. Just didn't want to admit it. 
