First kart build, lots of trial and error!

[mysteryboy28]

Having wanted a go-kart since I was a kid, and finally getting one at the age of 39 (then 2, then 3) - I'm now embarking on trying to build my own. Using mostly new metal for the frame and steering/suspension, and the rear assembly from another kart (as well as tires and other odds and ends) here is my progress. I'm learning as I go, especially that it pays to measure everything several times before cutting and welding. I have a cheap little 90 amp flux-core welder, which out of worry that I'm not making my welds strong enough, I'm over-welding everything (better safe than sorry?). I've gone through several spools of welding wire (I think I'm on spool number 8?), at $13-15 per spool. Eek. Next purchase: a real MIG welder.

 

[TorqueRanger]

Alot of your welds seam to just float on the metal and I see no preparation of the metal for welding..

 

[mysteryboy28]

I agree. The welder just doesn't want to do what I want it to do. As for prepping the metal... it's all new metal. What should I be doing to prep it better? It's not greasy, dirty, or rusty.

 

[Rust Addict]

Just a thought on your welds. Try grinding the edges of the metal with a 4.5 inch right angle grinder. The chamfer or thinned out edges on the metal before you weld butt joints gets you a weld you can trust after you grind it flush. If you not doing this before welding, don't flush up your welds afterwards or you could have some weld breakage.

 

[fowler]

also leave a small gap betwen the peices u are jointing as to let the molten weld sink into the gap

about 1mm will do

 

[TorqueRanger]

I agree. The welder just doesn't want to do what I want it to do. As for prepping the metal... it's all new metal. What should I be doing to prep it better? It's not greasy, dirty, or rusty.

Well clean your metal because body oils and everything that touchs the surface can contaminate the weld .. All metal comes with some kind of coating on it in order to prevent flash rust and just plan rust.

 

[mysteryboy28]

I'll try to apply some of the techniques you guys are suggesting, but I really think I just need a higher-powered welder.

Meanwhile I made some more progress on the kart. Got the rear axle assembly attached, although i dinged the heck out of the side of it trying to pound the axle back into place. I think it's just cosmetic, not going to affect the integrity of the assembly. It was pulled off of the blue kart in the pictures.

Also here's a couple of pics of my first 2 go-karts. Manco Dingos with 11hp Honda and Honda clone motors. Lots of fun, but spent a lot of time fixing them!

 

[TorqueRanger]

Well first off what kind of welder are you running and how many amps ????

 

[mysteryboy28]

90 amp flux-core, no gas.

 

[fowler]

unless u are useing tube with 1/4 inch wall thickness then it should be fine

u should blow holes in the tubeing

try slowing down when u weld
or turning the apms up and wire speed down

 

[kyjohn]

Make sure you have a big enough outlet for your welder, If your not getting enough current to the plug in on your welder it won't weld right. Dont use extention cords unless they are large enough to supply enough current to the welder also. Some people don't know this and end up getting cold welds. Just a thought...

 

[mysteryboy28]

I figured using an extension cord wouldn't be good for the welder. Running off the 110 circuit in my garage, maybe it's getting a weaker connection than it should? I totally plan on getting a better welder for my next project! Although if it's a 220 I have no idea where I'll plug it in. Maybe build the go-kart in my basement? Lol.

 

[kyjohn]

I figured using an extension cord wouldn't be good for the welder. Running off the 110 circuit in my garage, maybe it's getting a weaker connection than it should? I totally plan on getting a better welder for my next project! Although if it's a 220 I have no idea where I'll plug it in. Maybe build the go-kart in my basement? Lol.

If you get a 220 welder just run you a dedicated 220 volt circuit
for it, it's not hard to do at all. Just make sure the power is off on your breaker box.

 

[mysteryboy28]

Put the old roll-cage on temporarily just to get some ideas. Starting to look like a real go-kart now!

 

[kyjohn]

Looking good !!!

 

[mysteryboy28]

Rear suspension installed! Need to add a couple of cross-braces, you can see where I clamped a piece on to see where it would go.

 

[mysteryboy28]

Debating whether to go with foot or hand operated gas/brake control. What do you think?

 

[kyjohn]

I think you would be better off with foot controls..

 

[landuse]

Is your engine mount on your swingarm or is it attached to the frame?

 

[mysteryboy28]

Engine mount is on the swingarm. I basically chopped the back part off the old blue go-kart, attached that to the new go-kart with the "hinges" and shocks.