Go Kart build for the grandkids

[Rando]

Decided to build a cart for the grand kids and give me something to do! Turned out to be way more of a project that I give it credit for. Built a lot of things out of wood in my life, but this was the first all metal build. Bought the plans for a spider cart, and started with the build till I started my own modifications. I wanted brakes on all 4 corners and wanted it to turn better than a solid rear axle cart. So I bought a Chinese parts group that included front upper and lower control arms, hubs and brakes. Rear axle with a diff and brakes. Also after researching cost of motors and torque converters, I decided to buy a ATV replacement motor with 4 speed trans and reverse built in. One thing about buying Chinese parts, no documentation or information on anything.

 

[landuse]

Welcome to the forum!!

 

[Rando]

the build

Started with the plans as drawn, working in the bought parts, mocking up to see how it will work. Work on the front end geometry.

from the first photo in this group to the last, notice I had to refab the top shock location. cut and modify the steering rack almost to the point of no return. the unit I got was way to wide for this build. Width was set by rear axle and finding rims to go over the brake calipers.

 

[DukeKL]

That looks like a wonderful design! Can't wait to see the final results.

 

[Rando]

3 pedal setup

Adding the front suspension assembly to the main frame and starting the cage

Adding the front suspension assembly to the main frame and starting the cage

the engine selection made this a 3 pedal build

 

[Karts of Kaos]

welcome, looking good. so you are a granddaddy building the granddaddy gokart. that's cool

 

[Rando]

More build photos

More from the build. I have it completed, but now debugging. I have 2 items that are being redesigned. The gear shift linkage and the jack shaft. motor has too much torque for the jack shaft design in these photos

 

[mckutzy]

You have the motor independent from the swing arm.
The best approach with this rear end, would be to have the motor/jackshaft/swingarm all on a swingarm assembly.. they would move together unhindered and when setup right, a harmonious movement.

 

[Rando]

Final Assembly

Yes I considered that set up but was concerned with the shifting mechanism. All the bikes I owned over the years I noticed were sometimes difficult to shift with direct connection and your foot and the original design here proved it to be the same issue.

Yes I considered that set up but was concerned with the shifting mechanism. All the bikes I owned over the years I noticed were sometimes difficult to shift with direct connection and your foot and the original design here proved it to be the same issue.

Final assembly, test drove and now in redesign of shifter assembly and jack shaft / idler assembly. Also have not been able to get the brakes bleed, even with compressor assisted vac system

 

[Kentucky Boy]

I like it. Nice work!

 

[Karts of Kaos]

looks pretty cool

 

[Rando]

Thanks

I suspect if it wasn't for this odd year that I ended up with a 5 week stay at home order from our Governor it still may not even be a rolling chassis yet.
Still pondering the redesign of the jack shaft and idler sprocket. Shifter mechanism I believe I have solved just need centering springs to finalize it.

 

[landuse]

Nice work!!!