karasaki 500cc Kart Project

[T.E.D. Jordan]

Thanks, I'd hope so. May be a while before its done but I try to work on it fairly often

Jordan

 

[jareeB]

Got the rear engine bracket finished. Modelled and exported it in AutoCad then it was CNC machined:



bare metal form after all the pieces were pressed and tigged together:



Quick check for fitment:



Etch primed to hold off the rust for now:



Fitted after it dried, then I bolted the two RH thread rose joints to the bracket, happy with the fitment:



Hopefully I'll have the front solid mount engine brackets soon.

Jordan

solid mount engines are so nice.

 

[jareeB]

Nice welds

nice welds???? those welds are fing perfect!!!

 

[T.E.D. Jordan]

solid mount engines are so nice.

They have hard rubber bushings in the engine mountings themselves front and back. Should take a little of the vibration out, but not alot. Ultimately its got the same vibration dampening as it had in the motorbike though.

Jordan

 

[Lynx_Genisys]

I always wondered that with the whole karting thing..

I know with the dingo, I can feel my brain rattling, to the point my vision goes blurry, just from the vibration of the engine..

I didnt realy mind it.. think i actualy enjoyed it.. but some part of me deep down thought "theres got to be a better way!" lol

Maybe if i chopped down like say an old semi truck mud flap and put it between the engine n mount.. nice n tight.. would likely do wonders! but meh. i am kinda lazy.. hehe..

I like how you're doing hte adjustable thing there.. with more or less kinda like turnbuckles.. I will deff have to keep that in mind!
(Okay, im noob to karting.. maybe thats a common thing to do.. but first i seen! )

 

[bighead]

Thanks fella. You're right about that, but I'm going to try and find some 11" tyre'd wheels for the front albeit slimmer! puts the front at a decent height for ground clearance and tyres should be easier to locate

Jordan

When I built my Bar Stool Racer from a shifter kart I put wide front slicks on it. It did not want to drive right. Perhaps scrub radius if I remember right.

Not a steering export as you can tell. But thought it was worth mentioning when your looking for wheels and tires.

Here is pics of the original wheel. And then the wheel I tried to use. As you can see big difference. There were other factors as well. But I remember people telling me the wheels could be to wide for my spindles.

Good luck. I hate steering work.

 

[T.E.D. Jordan]

I always wondered that with the whole karting thing..

I know with the dingo, I can feel my brain rattling, to the point my vision goes blurry, just from the vibration of the engine..

I didnt realy mind it.. think i actualy enjoyed it.. but some part of me deep down thought "theres got to be a better way!" lol

Maybe if i chopped down like say an old semi truck mud flap and put it between the engine n mount.. nice n tight.. would likely do wonders! but meh. i am kinda lazy.. hehe..

I like how you're doing hte adjustable thing there.. with more or less kinda like turnbuckles.. I will deff have to keep that in mind!
(Okay, im noob to karting.. maybe thats a common thing to do.. but first i seen! )

When you've got no suspension, wheels that are reasonably hard and every connection between the kart and wheels are solid along with the seat mounting its a recipe for a real bone shaker. The idea you have with the mudflap isnt a bad idea. I've tried it myself wih 12mm rubber on a pit-bike engined kart I built and there was a slight improvement, but even tight the chain would slacken twice as often.

Re. the rose joints, i'd guarantee something similar has been done before even though I havn't seen it before myself. Should work ok hopefully!

When I built my Bar Stool Racer from a shifter kart I put wide front slicks on it. It did not want to drive right. Perhaps scrub radius if I remember right.

Not a steering export as you can tell. But thought it was worth mentioning when your looking for wheels and tires.

Here is pics of the original wheel. And then the wheel I tried to use. As you can see big difference. There were other factors as well. But I remember people telling me the wheels could be to wide for my spindles.

Good luck. I hate steering work.

Thanks for your input fella, I do appreciate it.

You are correct re scrub radius, although alot of karts etc still do not try to cock the inside rear wheel during turn-in which on a fixed axle helps greatly, as it causes the width of the front tyre to receive a larger foot-print on the ground on the outside edge during turn-in. I've kept rigidity through the final frame design to maximum but due to the placement of the engine, driver, ancillaries and weight of all the above with the extra length I've anticipated even with my planned steering I'm going to experience reasonably poor steering in comparison to my race kart chassis.

I've followed this in the past - Not this exact article but its well eplained and free on this site: http://www.karting.co.uk/KandK/Tech/KartSetup.html

Most of my time on this kart will be spent sideways or going fast in a very straight line lol.

EDIT - P.S. Thats a lovely bit of kit you have there, love the stool racer!. Also I'm not as familiar with american cars but is that a nova in the background?

Jordan

 

[T.E.D. Jordan]

Small update,

I cant continue until I have got the front engine mount bracket machined and tig'd together, this mount is to be welded directly to the chassis and acts as a pivot point for the rear engine cradle that adjusts chain tension. Its designed so that it clears the motor, including the protusion of the oil filter although it won't allow me to change the filter in situe, which I'm not bothered about anyway as I doubt I'll ever really need to change once its got a new one. It also fits over the tube diameter I'm using snuggly -



As I don't have a tube notcher at the workshop I drew a quick right angle interpenetration for the tube that carries the front engine mount:



Love that method, so quick and simple and with an accurate printer, prints to size perfectly. For those of you who are unaware of interpenetration and, like me, do not have immediate access to a tube notcher look it up or I can send some literature your way I learned back in school. (5 years ago now ). This is printed, cut out and wrapped around the tube you intend to notch to. It produces a perfect zero gap joint for maximum strength and obviously is very neat! I'll take a better picture tomorrow that illustrates it better but its such a perfect fit between the bars. This pic shows it has a slight prep to the inside edges, as the nature of the notch makes the top thin, it is better without a prep as ultimately it will burn through the wall anyway:



Hopefully have more done tomorrow!

Jordan

 

[newrider3]

I used this program a few times when building my kart (eventually just started doing them by eye), it works pretty well.

http://metalgeek.com/static/cope.pcgi

 

[T.E.D. Jordan]

Got a chance to work on the kart again today besides the weather. Went to total engineering developments to get the front engine mount bracket:

On one of the cnc mill beds:


one finished side:


Assembled - plates press-fit between both shafts, then needs to be welded yet, other things made me stop working though, so I offered it up to see what kind of fit over the tube I had:







With this knd of weather I had to crack out a couple toys from storage:







More updates asap but will have to wait for the snow to go:

Jordan

 

[Doc Sprocket]

T.E.D.- That's looking awesome- very well engineered! I was wondering about the rose joints in the motor mount, but I see the point now, very good! That thing's gonna go like a cat on fire, if you can actually get some traction!

Could you please hook me up with that tube notching ifo? I'd very much appreciate it. Thanks- Chris

 

[newrider3]

See my link above, basically the same thing.

 

[Lifted94XLT]

This looks like an awesome build with GREAT work and fab skills!! I'm planning on doin the same thing with a KZ550 I have...... in for updates.

 

[Morte]

Looks cool

 

[bighead]

EDIT - P.S. Thats a lovely bit of kit you have there, love the stool racer!. Also I'm not as familiar with american cars but is that a nova in the background?

Jordan

Yes it is an 1965 Chevy II Nova.

 

[T.E.D. Jordan]

Thanks for the interest guys

I hope to get back on this soon, buying the seat next, gives me some layout options.

That chevy nova is pure sex very nice!

Jordan

 

[Lynx_Genisys]

no vids yet??

lol..

jk jk

just checkin in and wanted to compliment your quality of craftsmanship...

and mostly just to let ya know, im still watching and waitng and admiring..

I understand the snow thing.. we've gotten like 2.5 feet of it in the last week.. *Sighs*

I want a heated garage with all the fab toys.. but.. the inlaws are retiring in about 2 yrs and gona sign their hous over to us.. hehe.. plenty big enough heated garage to build karts in.. and hose with wood fireplace!!

but i dont think i can wait seeing things like this!!! c'mon spring!! ugh

 

[T-man]

jaree , that is a very good mount that your doing. I'm going to have to do that also. I haven't had any idea how I was going to do it untill I saw your stuff. Great design, if you could keep the pictures comming, that would be very helpfull to me.
Again : Great build

 

[Gutteer]

this is a kinda dead thread but i want to see this finished

 

[Mikeythai]

You're not the only one. The power to weight ratio on that ride is awesome!