Full suspension 250cc Shifter Kart build.

[Degerovita]

Started off as a small kart build that has grown into a small buggy build.

I bought a older suzuki 250cc quadrunner missing only the rear wheels but the motor had no spark for $50. I cut the front suspension off and widened it 12", cut the hard tail axle and mounting points, then fabricated a swing arm out of it. The motor spark issue is the coil and I will be ordering one asap.

Before the welds were ground down a bit, waiting to mount the skid plates.


Now I am getting ready to buy the round tubing to finish the frame and then installing the misc tidbits (seat, steering wheel, shifter). What alloy and wall thickness do you guys recommend? Close to 1" O.D. would be nice but if I should go bigger let me know.

The Kart will have a full roll cage, Suzuki 250cc single piston 4 stroke w/ reverse, electric or pull start w/ compression release, head lights, brake lights, racing seat with 4 point harness.

What I'm looking for:

a speedometer w/ cable (axle is set up for it)
Small Rack and pinion

Let me know what you think.

 

[t0x1k]

I'll be keeping tabs on this thread!

 

[NJOHC]

That is going to be sick when you're done with it! I wish I was as lucky as you to find deals like that.

 

[Degerovita]

Craigslist, posted a want ad and got a call back that day. Also I'm looking at making this street legal. Ive combed the Ohio BMV website and got no where, and the people at the local agency havent a clue on what or how to do it. Anyone done this using a non street legal motor?

 

[t0x1k]

Basics to being street legal are

-head lights at a certain height
-turn signals
-brake/parking lights
-windshield
-dot approved tires
-brakes
-seat belt

All states are different. Like jersey, not a chance. Unless you were the mayors close relative.

 

[Degerovita]

Just picked up a set of 25" carlisle badlands on chrome rims that also fit my 23" dunlop kt403's. Man I love craigslist.

 

[NJOHC]

I wanted them for my rear tires but they dont make any that fit my wheels.... none that I could find anyway. Im gonna be jealous of this thing when your all finished with it! haha

 

[Degerovita]

What I'm working on currently:

Wheel adapters/axle spacers. They will adapt my 4x130mm hubs to 4x156, and will space the tires out aprox 3" per wheel.

Rebuild axle housing. Bearings and dust boots.

Still looking for a racing seat and rack and pinion steering.

 

[Degerovita]

Update:
Picked up a racing seat and got the tubing in today. 1020 1" o.d. x .083" wall. Mocked up the kart and took all my measurements. Looking for a tubing bender as the conduit bender I have wont bent this thick of steel.

Pic:

 

[mike75925]

question, why the rack? it should steer easily enough, unless you are going with a 'small' steering wheel.

 

[modelengineer]

I agree, it will steer much better with a bell crank system. The kart won't be heavy/large enough to warrant a rack as far as I can see.

 

[Degerovita]

Recieved steering wheel w/ quick release hub (anti-brother insurance), 4 point harness,

question, why the rack? it should steer easily enough, unless you are going with a 'small' steering wheel.

I have several karts already and the bell crank system it too "short" and at high speeds gets a bit shaky. I'm experimenting with a hybrid gear reduction/bell crank system at the moment. Should be lighter than a rack and pinion, and still give me "slower" steering. I am using a 10" steering wheel.


Project is kinda on hold untill I finish making my tubing bender. Just have to finish the follower die and make the handle.

 

[That One Guy]

WHOLE-EE-JIZZ, that's sweet!

 

[dpaxson]

that looks sweet! but i doubt you're going to be able to make it street legal. i'm from cleveland and my experience with ohio bmv people has shown that most of them have no idea how to do anything but renew your license.

 

[NickRummy]

Sweet project! I'm in Akron too, I'd be interested to see this thing run.

 

[Degerovita]

Got tubing in and delivered all parts and materials to the local buggy shop. They are fabing up the frame and just tacking it together. Should have it back in a week or two so I can finish the welds, install bracing, mount seat, seat belts, motor and other hardware. Things left to make/buy are:

petals
wheel hub adapter/spacers
shift linkages
jack shafts
mount steering wheel
gas tank
air box
battery

 

[Daveon]

More pics

 

[Linksep]

Street legality will likely be pretty tough unless you make it a trike, and even then (in Minnesota at least) you have to sit "astride" the vehicle and steer with "handle bars"...

I think probably all of us fantasize about making street-legal karts though.

 

[Degerovita]

I pick up the frame tomorrow. so exicited. will post pics.

 

[Kenny_McCormic]

Its not that hard to register a custom car, at least in MI.

http://www.michigan.gov/documents/BFS-72__09-03__83315_7.pdf
http://www.michigan.gov/documents/TR-54_38480_7.pdf