Azuza frame Build

[OzFab]

Unless you have the ability to turn the barrels from a solid billet, Jims sketch is the way to go...

 

[chancer]

Frame Mods
Before I started looking into spindles last Friday. I finished up my front extension, and made the seat frame. also changed the steering shaft mounts. The frame came with a solid bar support that attached on each side. So I made a single center tube mount for more knee clearance. My actual steering shaft is a 5/8axle I umm... "acquired" at work from a broken HF Dolly. It fits perfectly inside 1/2" gas pipe after you grind the weld off the inside. Got the upper support lined up really good with the lower and nothing binds.
Yes if you look closely me bends are NOT perfect. I only have the Harbor Freight "pipe" bender. (craigs list $40) So they are actually not too shabby. I takes several bends to make a 180* seat hoop. and not kink anything.

 

[Poboy kartman]

But you have a kink in the seat hoop.....did you pack the tube with sand first?

 

[chancer]

But you have a kink in the seat hoop.....did you pack the tube with sand first?

That's a dimple!
Actually that inner hoop is a thinner wall tubing so yes it kinked easier. It also did not end up...(how do say "square" on a round bend) So you can see the patch where I cut and sectioned it to be square so the outer hoop would fit correctly. The outer hoop is heavier tube and did not kink errr.... "dimple".
I have used sand before but I did not really notice the difference. Besides my little boy gets mad when I steel his sand box sand:toetap05:

 

[landuse]

But you have a kink in the seat hoop.....did you pack the tube with sand first?

That's a dimple!

Looks like a ding to me. At least you don't have 285 of them.

 

[Poboy kartman]

.....but he's not done yet...he could ding it up more....

 

[chancer]

Ok ding dimple...? Here's the good part I got the sheet metal on the seat and the rest of the floor pan. So the "divet" is no longer visible.
I also filled in the lame factory joint in the frame where the 2 bars come together at the front. Wow it looks like $#!T in the photo! But it actually came out pretty good.

Today I got the tubing to make my Custom Spindle Barrels with bearings. Yes Jim heavy duty tube. The inner one is even DOM cause that all the had in that size.

 

[firemanjim]

 

[chancer]

One question on my Spindles. I just got the 5/8 Bolts for the actual Spindle. I thought I was smart getting grade 8 bolts for strength, then I remembered something about Grade 8s being brittle and more difficult to weld. Is that true? It is no big deal cause I also got standard grade 5 for the Spindle bolts. Which would be best for the spindle? 8s or 5s.

 

[firemanjim]

I always use 8's..... Use high heat to get a good penetration. I've never had one break. Bend a little,.... Maybe.... BUT that is with much abuse....
Look up the shear strength of the bolt size you're using, in a grade 8....... Do you think you will put your kart through that much abuse?

 

[chancer]

Yeah I don't think I will break them.
The Shear strength is 27,611 lbs and the ultimate tensile strength is 150,000 lbs.

 

[chancer]

Got my Spindle Barrels made With Bearings! These are cool. I think later I will do another thread with lots of pics and details on exactly how these are made. But it just follows the plan discussed earlier in this thread. Thanks again to Jim for the advice and details that perfected this design.
These are way better than metal on metal and compared to if you bought as set of cheap metal on metal for $27 + shipping. They only Cost about half that. including Grade 8 Spindle bolts @ 3 Bucks ea

 

[Poboy kartman]

Got my Spindle Barrels made With Bearings! These are cool. I think later I will do another thread with lots of pics and details on exactly how these are made. But it just follows the plan discussed earlier in this thread. Thanks again to Jim for the advice and details that perfected this design.
These are way better than metal on metal and compared to if you bought as set of cheap metal on metal for $27 + shipping. They only Cost about half that. including Grade 8 Spindle bolts @ 3 Bucks ea

LOL....Joke's on you....I made it to grade nine!!!!!....JK....

GOOD JOB!!!!!......I'm liking it!!!!

 

[chancer]

Stay tuned Doug (can I call you Doug)
Next I am making my pedal mounts. I want to use the reinforced design you used on the "Thug Kart" I already have in my parts drawer some extra all thread connectors and fender washers?

 

[Poboy kartman]

Stay tuned Doug (can I call you Doug)
Next I am making my pedal mounts. I want to use the reinforced design you used on the "Thug Kart" I already have in my parts drawer some extra all thread connectors and fender washers?

Go for it!!!!! ....You can call me Ray...or you can call me Jay....(JK)....no...you can call me Doug....my mama did....and....that worked out okay on "Thugkart"....but...the proper sized bushing might be even better...and yes...all-thread. connectors and fender washers is what I used....and a teeeeny....teeeny...teeeny...bit of Bondo to cover that up!!!!

 

[chancer]

Oooh now I am thinking Oilite bronze bushing. but that costs money I hate spending money almost as much as I hate metal on metal worn out bolt threads.

 

[firemanjim]

Great job on the spindles!
Those should last you a while, and make turning with one hand a lot easier, while you hold your beverage of choice in the other.....

 

[chancer]

Been busy on the kart, got a bunch of little stuff done. Mounted my pedals. I Drilled and support for the throttle cable. Little tab for pedal return spring

 

[chancer]

Been busy on the kart, got a bunch of little stuff done. Mounted my pedals. I Drilled 1/2" holes in the frame and inserted bronze bushings for the bolts to spin on
also welded the support for the throttle cable. Little tab for pedal return spring. moving right along

 

[chancer]

OOPS. sorry for the double post!
Anyway I also finished up the steering. Got my pitman arms welded on and installed my tie rods.
I made these tie rod ends last year for a different kart, so they were handy. I used a similar method to the DIYGK "plans.
http://www.diygokarts.com/kart-plans/steering-plan-assembly.html

But I improved it some. Using 3/8 all thread for the rod, Then I welded 1/8" flat stock to 3/8 all thread connectors. and added double nuts for security.
They do not have reverse threads so you have to take them apart to adjust but they work great and were DIRT cheap.
Smart phone camera! Sorry upside down pics, again