Manco 415 Restore

[Soapbox]

Hi, just joined, so here is the before pics....
there's a bit more on ....but not much yet!
http://soapbox.moonfruit.com/vintage-manco-gokart

Rich

 

[Functional Artist]

Hello Rich,

Welcome to the forum!

Nice Kart.

Nice pics. Top & bottom view. Original & kool!

I wouldn't flip it over too often.

Gas engines don't like to be upside down.

Oil, gas & everything goes into places it shouldn't.

Keep us posted!

 

[Soapbox]

Advice required on a Manco 5” half rim…I’ve already repaired one half rim,
glued a bit back using epoxy and finished with metal filler as in pic. It might last?….I‘ve now got another half rim with three lower sections on the outer rim.
In other words three slight dents in the rim.

Any ideas how to reshape it, “gentle heat” ? I’m scared a hammer, cold, will just break the rim? Never used heat on Manco Monkey Metal…any ideas ?

Rich

 

[Hellion]

Great find on the kart. Amazing how far and wide they go. Alas, the salty ocean air hasn't been too kind to it but it's nothing a little new sheet metal cannot cure.

I've got that same kart albeit with live axle propulsion. I've got to post that build thread...

The Manco wheels are cast aluminum as far as I know. I think Kelly Wood has repaired a few with JB Weld built up in layers and then ground and shaped to fit. He's also, if I recall correctly, reattached the broken rim piece(s) with that same material (which is a high-strength epoxy).
EDIT: no sense guessing about it, here's the thread>> http://www.diygokarts.com/vb/showthread.php?t=19432&page=63

Another alternative is to see if you can source an intact wheel half. Might try on the For Sale or Trade forum.

Still another alternative for at least retaining the vintage and "spiffy" aluminum wheel look is to seek the Azusa Tri-Star rims for the same size tires you have. They are a bit pricey though and more so if you ordered them from the States.

 

[Soapbox]

Hi Hellion, interesting, that’s more or less what I’ve done with the one in the pic.
I think it would be flattering to call it Aluminium, it seems very brittle, more like a Pot Metal (Monkey Metal). May have a high(ish) alloy content? But I think it’s very low rent.

If they can be found people seem to want a lot of money for Manco rims! Especially considering the quality…but that’s….supply/demand!

Postage from the states/£ value makes stuff from the States expensive, so I try to avoid. May have to go modern kart wheels but that’s not the look I'd like.

So yes I’d like to keep the “spiffy” vintage look.

May try the “gentle heat” then fix it if it breaks!

Rich
(and get yours posted)

 

[Hellion]

Well you seem to have matters well in hand for your wheel issues. I should use the same repair method on mine although present plans do not include utilizing the two broken rims. Spares or possible trade fodder might be considered.

Your weblog mentions replacing the engine but the Briggs is imminently rebuild-able and cheaply too, depending on what's wrong with it. I would imagine there's a decent supply parts industry in place in the UK since they were an export item.

I've got the same engine on my Manco 485 (cage over engine variant) and while it had almost zero compression, it was found to be a bad valve which needed to have its clearance/valve lash adjusted. Otherwise the engine has seen low hours and will be going back together with almost all its original parts.

 

[Soapbox]

Hi, The engine probably is quite rebuild able but I’m told it was low on compression and a bit smoky, that was about 2005ish when the kart was last used. It then lay outside for about 5 years then stored in a damp shed for another 5-6 years…
Not had a proper look at it yet but my cheapest/quickest option is to replace it with a new Honda gx160 I just happen to have…and since it’s doing nothing.

Perhaps the Briggs will be another project? I’d happily give it away to someone who would rebuild/use it. Get a shipping quote! It’s yours!

Back to wheels….this is the worst ½ wheel, now has the three bends in outer rim removed as best I can but now has two fractures!
If I was doing it again I would heat the area and then use grips to gently bend, that was how I did the one that didn’t fracture. The other two I used a hammer= fracture!
Live and learn. I’ll know next time.

The rim has a fair bit of corrosion, looks like a few hours work but I’m sure it can be saved!

Rich

 

[Hellion]

Hi, The engine probably is quite rebuild able but I’m told it was low on compression and a bit smoky, that was about 2005ish when the kart was last used. It then lay outside for about 5 years then stored in a damp shed for another 5-6 years…
Not had a proper look at it yet but my cheapest/quickest option is to replace it with a new Honda gx160 I just happen to have…and since it’s doing nothing.

Perhaps the Briggs will be another project? I’d happily give it away to someone who would rebuild/use it. Get a shipping quote! It’s yours!

Back to wheels….this is the worst ½ wheel, now has the three bends in outer rim removed as best I can but now has two fractures!
If I was doing it again I would heat the area and then use grips to gently bend, that was how I did the one that didn’t fracture. The other two I used a hammer= fracture!
Live and learn. I’ll know next time.

The rim has a fair bit of corrosion, looks like a few hours work but I’m sure it can be saved!

Rich

Hey now, you were the one wanting to retain the kart's vintage looks. Well the Briggs is vintage and 'old school' charm and it fits the kart to a T.

I'd at least open the engine up and see what's amiss. You'd be surprised how grungy an old engine can be on the outside versus the inside which is basically a sealed environment provided of course it retains a complete air filter assembly, the oil filler caps are in place and it has a spark plug installed.

I wonder if the Manco rims can be repaired professionally or with professional means? Tig welded back together?

 

[Soapbox]

Hey now, you were the one wanting to retain the kart's vintage looks. Well the Briggs is vintage and 'old school' charm and it fits the kart to a T.

That’s not playing fair, that’s my heart strings you’re tugging at!

So here’s the deal, we get on with the wheels, we then make a start on the chassis.
I then have a look inside Mr Briggs…………..

TIG weld Manco wheels, I’m sure a skilled welder and the right rods (with experience on this type of metal) could do it. There’s also now these “marvel rods” that solder/braze/weld aluminium at about
300-350 http://muggyweld.com/alloy-1 not saying this one would work, but there’s quite a few different ones available. Always wanted to try them….perhaps I should have!

Rich

 

[Hellion]

I'm just going off of what you told me; I'm not trying to manipulate the situation.

Cheapest and quickest method will always be to use a cheaper, more advanced, mass-produced small engine from Asia, but are you really learning anything by doing so? I say keep it, refurbish it whether it makes any logical sense or not and use it at least once. It is also by no means an ordeal to bolt and un-bolt it from the kart as desired. It's not like we're dealing with the complexity of automobiles here with hoses, wiring and all...

Those marvel rods look promising. I'm gonna have to check into that option--thanks for the info.

I also noticed your seat back was missing in the photos. Is it missing in action or just not photographed? Apparently that's a separate piece that is fastened to the frame with nuts and bolts.

The flat canvas strap in the center of the seating area was a factory addition--something for the passenger to hold on with I presume.

 

[Soapbox]

The seat back/frame is present (but not quite correct), it’s sheared off at the brackets, it looks like it was then welded to the frame and then sheared off again?? The nuts/bolts and brackets are still rusting on the kart. Top bit of seat padding is missing.

If you try some rods, let us know the results! I’m tempted to buy some and try them myself, but hey I’ve got knackered old engines to rebuild

The strap "something for the passenger to hold on with I presume."
Me too… but Factory?

Rich

 

[Poboy kartman]

Yep...my Manco has one and that's what it's for.

 

[Hellion]

The strap "something for the passenger to hold on with I presume."
Me too… but Factory?

Yes. Yours appears to have been cut and tied off to the side but it is supposed to go over the seat bottom and fasten to the bracket there at the rear.

Just little trivia tidbits. Thought you might enjoy.