Carter 1802 Resurrection Dream

[DanPorges]

Good Day Everyone....

A quick forum search was actually pretty fruitful that I am not the only person with this pipe dream, but unfortunately I think everyone has hit similar dead ends and the threads I found were all closed to additional posts. Here is what I found to avoid rehashing it all:

(1) Carter 49CC Help | DIY Go Karts
(1) carter go kart wont move | DIY Go Karts
(1) Carter bros go kart | DIY Go Karts

Through this I officially determined my Kart to be a Carter Brothers 1802. Its powered by a Tecumseh TCII (TC300) 2 stroke engine and has the rototiller-like worm gear drive train. Here was one some of the information I have from the above threads:

Spec Summary: Super Wheels (archive.org)
Parts diagram (Different Body, Same Chassis/Drivetrain)

 

[DanPorges]

@itsid

You had stated in one of the threads above the following:
well, the worm gear is basically a "one way" gear
as soon as the drive shaft is in place, you cannot turn the wheels;
not without freewheeling hubs on them at least.

the pinion is trying to push the worm hundreds of times harder than it's trying to turn it;
that's by design. (huge gear reduction, slow running but with good torque)

Assemble the drive shaft, then turn the clutch (the bell in the upper end)..
Does the shaft on the bottom rotate?
slowly but without much effort?
Well.. then you're good!

This makes sense with what I have seen. I will take some videos or pictures today, but when I turn the bell the left drive axle and hub turn, very slowly, and so I believe the gear box is working fine. The problem I see is the aluminum sleeve that is over the axle is turning, not just the hub and brake and such. I would expect the aluminum sleeve to spin freely from the rest of the assembly as that is where the u-bolts (Part 21 in diagram above) clamps the axle to the frame. However, if its not spinning freely I would expect that means the axle wont turn.

My biggest issue thus far is I cannot seem to get the axle apart to see how all these pieces are related. Any tricks anyone knows on pulling this thing apart? Are there usually set screws or is this just a WD40 and brute force situation?

 

[Denny]

Boy, your in some uncharted territory here in recent history. PB Blaster, Gibbs or some other penetrating oil would be better than WD though. I doubt any parts are still available for the axle though. Might be better upgrading.

 

[DanPorges]

Thanks, certainly seems like it’s going to be a challenge. I will get this axle apart. I have it down to a couple bushings and two sleeves on either side of the band brake drum and the gear box, managed to get the entire other half apart.

 

[ezcome-ezgo]

That's going to be a lot of work to go 12 mph.

 

[DanPorges]

That's going to be a lot of work to go 12 mph.

Especially considering my son’s Porsche power wheel is modified to dual 20v batteries and already goes faster