First time out.

[Psychanik]

So here we go! This is my first time messing with a go kart aside from driving them a few times as a kid. Being a chronic do it yourselfer I opted to purchase a thrashed chassis and see where this went. Once I got it home I realized just how much I of a chore it would be to restore it.

So here is my Streaker 2 seater in all its greasy, rusty glory.

 

[chancer]

Looks like a good set of Bones. You could make a great little kart there. But you will need 3 or 4 pillows so your "driver" is able to reach the pedals.

 

[Psychanik]

I noticed a few problems right off the bat, such as the bent spindle mount and the caved in front bumper, and neither one really bothered me since I have a little fabrication experience. But I admittedly was not fully prepared for the hacked rear axle setup. It's a live axle, but whoever last assembled it put both locking collars on the same side of the rear bearings. So whenever a right turn was made, the whole assembly shifted over allowing the brake drum to gouge a deep score mark into the frame.

The kart came equipped with an archaic 7/8" jackshaft setup that I can only assume came from some piece of farm equipment. I was going to attempt to use it, but for some reason no go kart company I could find on the Web sells sprockets with a 7/8" bore. Coupled with the fact that both chains were uselessly rusted and the teeth on all 3 sprockets were excessively worn, the choice was made to junk the whole driveline and start over.

 

[Psychanik]

Looks like a good set of Bones. You could make a great little kart there. But you will need 3 or 4 pillows so your "driver" is able to reach the pedals.

Luckily that seat came with sliders.

 

[chancer]

If you are wanting to use a jackshaft, it will help make it possible to slow down the kart so Jr can drive it. My point is if there is anything usable on the jack shaft I think you can get 7/8 bore gears at an industrial supply place like Grainger or fastenal. Or just copy what you have there. 5/8 pillow blocks can be found for like 10 bucks, and you can easily get 5/8 gears and shafting. I use MFG supply. Every order always ships for 6.99. I try to order as much as I can on 1 order, so its almost like free shipping.

 

[Psychanik]

I had thought about getting a jackshaft kit I found, but the budget wouldn't allow it considering all new bearings, sprockets, brake drum, chains, and of course an engine would be needed. I had incorrectly assumed that more of the existing parts would be useable.

So for the time being it will have the standard 10t clutch 60t axle combo. I have to keep this project simple in the interest of time and currency alloted. Then there's the fact that I'm building it on my front freaking deck and sooner or later the wife will get fed up with another unfinished project.

That being said I worked diligently over the following week and a half disassembling, cutting, welding, grinding, cussing, grinding, wire brushing, degreasing, and generally making the neighbors hate my guts to get the frame ready to paint. Although my fabrication skills have dwindled since the last time I worked on a racecar, somehow the spindle mount ended up functionally straight and a new front bumper was attached complete with buggered up welds.

 

[Psychanik]

Time for paint! My parents graciously agreed to let me set up a small paint booth in their garage. Little man picked the color and I'm super pleased at how it turned out.

(Sorry for all the sideways pics...I'm useless when it comes to technology.)

 

[landuse]

The kart is looking good. It is amazing what a little bit of elbow grease and dedication can do. You will love the kart when it is done

Whith tyres that size, the 6:1 ratio should be fine for you

 

[Psychanik]

Thanks a bunch! I spent a lot of time with various gear ratio calculators while trying to make the existing jackshaft gears work for me. I was aiming for something closer to 6.5:1 due to some of the terrain around here. But everything I found pointed towards 6:1 being the magic number with 13" tires so we're going with that for now.

All my research was done as a lurker on a couple forums but I'm starting to think I should've joined earlier so chancer could've said his piece about my 7/8" jackshaft before I had already ordered my clutch and axle sprocket. Oh well, live and learn right?

But since I'm a member now I might as well ask about the alignment. Assuming zero caster and camber would it be better to toe the front wheels in or out or set them up neutral?

 

[Psychanik]

Christmas came in July when the parts arrived one day last week...also a predator 212 followed me home. It wasn't until the engine was test mounted that I really felt that I was making progress. I was also surprised at the level of excitement my son showed after seeing the engine sitting on the frame. Felt good.

 

[chancer]

Search this forum for ACKERMAN. It will be the biggest help with alignment and handling. Look on the home page FAQs and Announcements. also a thread there called helpful links from the forum. Also look at Desert duelers new build recently he showed how he found the correct ackerman angle. Or ask. I found too much info and confused something really easy to do.
Oh yeah and my pics were always sideways too. I was using an IPhone. I found if I hold it horizontal and with my R finger to take the pic they come out right. Who knew!

 

[Psychanik]

So here it sits in current condition. I'd say 98% done. Still need to work out the alignment and replace the super bald front tires and inner tube that no longer hold air. Sadly that'll have to wait until payday. Also once I finished the rear axle and got the chain on I found that the axle has a fair amount of runout starting at the left rear bearing. It's not bent much, but it's enough that you can notice about 1/4" extra deflection in the chain. Not sure how much damage that could do to the sprockets, but the ride will be a little bumpy until I can afford to drop an additional $60 or so on a new axle.

I am however somewhat proud of the seat that consists of some foam slabs and fake leather found at the local hobby lobby. Finishing up with a lawnmower throttle cable and this things about ready to tear up some grass!

Any thoughts and/or criticism appreciated.

 

[Poboy kartman]

Oh yeah and my pics were always sideways too. I was using an IPhone. I found if I hold it horizontal and with my R finger to take the pic they come out right. Who knew!

Ummmmm.....besides me...(who can only go online with a phone....)...???

I'd say all the rest of the folks that didn't post sideways pics.....

I'd say Mensa won't be calling anytime soon.....but we're glad you figured that out....we thank you .....and our necks thank you.....

 

[Psychanik]

Yeah I figured it out. And the phone is my only connection to the web. One day when I'm all growed up I'll get one of them fancy computerizers.

 

[chancer]

Poboy??? If you can only get online with your phone... Why does your neck hurt? JUST TURN the Phone 90*. Yeah Mensa wont be callin you either.

 

[OzFab]

Finishing up with a lawnmower throttle cable

Any thoughts and/or criticism appreciated.

Please don't tell me you mean the solid wire throttle cable, those are no good for go karts, you need the twisted wire cable like a bicycle brake cable...

 

[Poboy kartman]

Poboy??? If you can only get online with your phone... Why does your neck hurt? JUST TURN the Phone 90*. Yeah Mensa wont be callin you either.

No....turning my phone 90° keeps the picture oriented the same way....it just changes which way it's oriented on screen....(in otherwords...it's still sideways) ....to turn the pic 90° ....I have to turn off my screen rotation....which enables me to read text whether my phone is sideways either way, upside down or right side up....no big deal, but some members have computers.....

 

[landuse]

So here it sits in current condition. I'd say 98% done. Still need to work out the alignment and replace the super bald front tires and inner tube that no longer hold air. Sadly that'll have to wait until payday. Also once I finished the rear axle and got the chain on I found that the axle has a fair amount of runout starting at the left rear bearing. It's not bent much, but it's enough that you can notice about 1/4" extra deflection in the chain. Not sure how much damage that could do to the sprockets, but the ride will be a little bumpy until I can afford to drop an additional $60 or so on a new axle.

I am however somewhat proud of the seat that consists of some foam slabs and fake leather found at the local hobby lobby. Finishing up with a lawnmower throttle cable and this things about ready to tear up some grass!

Any thoughts and/or criticism appreciated.

As far as i know, axles can be gotten for a lot cheaper than $60. Have a look HERE.

You might find that your chain pops off quite a bit

 

[chancer]

With all the sarcasm I forgot to tell you. Nice looking Kart.
As far as your axle. I see you have the same type of stuff I use. In my experience the bolt holes were larger on the sprocket than the hub(or vice versa). just by a little maybe 1/32+ the bolt being a little tiny smaller. Any way if all the play is on one end of the parts, It seems to act like a bent Axle. I just had to center everything carfully and it all straightened out. Not to mention locktite and grade 8 bolts, to hold it tight.

 

[Psychanik]

Unfortunately it is definitely the axle that is bent. I noticed it even before the sprocket and wheels were installed. I had thought of trying to fudge the sprocket a little by using smaller bolts and still might do. But for now I simply found the point of rotation where the chain was at it's tightest and adjusted from there. Hopefully it'll stay together.

As far as the throttle cable goes yes it's the solid core type, but it's what I had at the time. I don't forsee an issue since it's only about 18" of cable. The way this kart came to me it has a metal operating rod from the pedal all the way back to midway under the seat. Then it transitions to the cable. There's a fairly stout spring on said rod making throttle return instant. So while the lawnmower cable is not ideal, it seems to work so far.