Indy Kart Official Project Log

[Sdannenberg3]

Dear Blog, err DIY Go Kart people......
Today I ordered the steel for my new go kart project dubbed "Indy Kart". They man on the phone said that if he orders it today that it will be here tomorrow. Key word there being *if*.

I also went out and bought a cheapo cut off saw from Harbor Freight. (I think most of my tools are made by chicago electric LOL) I know I know, buy nice or buy twice but you know what? What about just buying cheap once? Hopefully ill finish all my cuts before the manufactures warranty is up and then if it breaks after that I wont care.

So my new project is officially started and I will keep posting updates so if anyone does care, they can see it!

For those of you that havnt already seen it. This is the projected look of the final project.

 

[Jerryburger]

This is going to be cool!

I'm impressed as heck with my Chicago Electric saw.... it made it the whole way through the Lowrider Project, without any problem at all. A friend gave me his when he saw my other one burn up.

That's nice work with the sketch program... I haven't tried my copy yet. Looks neat, though!

 

[Kenny_McCormic]

powah plant?

 

[Sdannenberg3]

Dont exactly know yet. Thinking about the 125cc Lifan clone dirt bike engine with a 5 speed. I already have an idea on how to set up linkages for the shifter.

I was looking for a used dirt bike, but I cant find any. I think im gonna just continue to wait cause $300 for a new engine is a lot of money for me to be spending. So ill just build the frame and wait for some old title-less dirt bike with a running engine to pop up!

 

[modelengineer]

Shifter linkage is easy to do. Hooking up a dirt bike engine is just as easy as a 'normal' kart engine, it just takes more time... although the engine mounts are a *little* more difficult, but still very simple. You will be very happy with a 125cc or 250cc engine.

 

[Sdannenberg3]

Yeah, Im thinking just a 125cc because of that whole money thing. Would it be worth buying a used bike for parts and take the engine, intake, carb, exhaust and all that or just get the engine new? Keep in mind that I also need brakes! Would I be able to come up with some way to use the brakes from a dirt bike on my kart? Can I get the brake disk on my axle?

 

[Jerryburger]

Is it going to be live axle?

 

[Sdannenberg3]

Yes it is. I already have the axle, its off my old kart. Its a 1" and has the keystone slot all the way across for it. I just dont know how the brake and brake hub assembly works on a dirt bike. Or can i use the disk and caliper off the bike, and the disk brake hub off my go kart now?

 

[modelengineer]

You can use the engine, chain, maybe rear sprocket if it provides an OK ratio, brake disc, brake caliper and the brake master cylinder. Buying a whole bike, preferably damaged so it's cheap, is the best option.
You will probably have to drill new holes on the brake disc hub to make the bike disc fit, but hubs are relatively easy to make.

So yes, you can use the bike disc and caliper and probably adapt it to fit your hub, but if not the hubs are cheap/easy to fabricate.

 

[Sdannenberg3]

Ok thanks!

And say that the sprocket will not work, where can you find different ones? Cause I would imagine that the chain size is different than the one I have on my go kart now.

 

[modelengineer]

Most bearing shops will be able to sell you sprockets. It is likely you will be able to use the rear sprocket from the bike you get though. With such a light kart it will still have good acceleration. On mine I'm changing from the original sprocket (around 35 teeth) to a 50 tooth, but mine is an offroad kart between 250 and 300kg.

You will need to find out what type of chain the bike uses, or buy a new primary sprocket as well. Motorcycle chain is classified by 3 numbers. For example most of the bikes I've been looking at use 520, 525 or 530 chain. All are the same pitch but with different widths.
If you can get the manual for the bike it should tell you what type of chain, or just ask on a forum dedicated to that bike.

But yeah, bearing shops can usually get sprockets.

 

[travisn]

farm supply stores have sprockets too, or just buy one for what ever bike you get, and make it fit, same with the brakes. mount the rotor to the axle and make brackets for the caliper... def worth it

 

[Sdannenberg3]

Just a quick little update, I didnt get my metal today But I took some parts off my old cart that Im going to reuse because I dont need to buy new ones. Took them to the grinder and the wire brush and got them all cleaned up. I hope the metal gets here tomorrow!!!!!!

*Have to finish taking the paint off the one spindle bracket there*

 

[Sdannenberg3]

10-17-08 Update

Yay, I got my metal today and finally got started!

I made all the cuts, and angles that I need and tack welded the back half of the frame together. Its coming along nicely!

 

[kibble]

Looks good! Nice job.

 

[Kenny_McCormic]

Very Nice!

 

[Sdannenberg3]

Today I finished welding my whole frame and welded on the axle brackets and the spindle brackets. I also got the steering wheel mounted (I was pretty proud of how I thought that up)

Its coming along nicely!

 

[kibble]

Wow dude, you're just moving right along and it's looking great!

 

[ed1380]

WOW thats awesome. i want one like that.

PS- you missed a spot welding

 

[Sdannenberg3]

hahaha yeah I actually see that! My welder is acting funny. It like wont keep a constant arc. I will start welding and it keeps stopping half way through. It only did it on the second half of my frame. And I am following my 25% duty cycle. Im actually probably only doing 15%!!! so it shouldnt be overheating.