Manco XTK Resto-Mod

[ShapeShifter]

I traded two RC trucks and a kids guitar for this. No idea which exact model Manco XTK it is but I think its in the 7xx series.

Best I can tell, a previous owner added the Predator 420 after the swing frame and axle broke. Looking at the "repaired" damage, I am guessing the swing frame and axle broke and jammed the sprocket in to the original engine. When the beef engine was installed, the genius installer decided to cut the rear cross frame to make it fit.

I have big plans for this and I already have a brand new axle for it. Here goes...

 

[Hellion]

That thing is huge; looks almost street legal and like, complete with all the comforts of a 2017 Toyota.

Where's the fun in that?

 

[Kartorbust]

Guess they didn't know you can buy a new axle online. Could use better lights I bet.

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[kenworth85]

you need to align your torque convertor

 

[ShapeShifter]

you need to align your torque convertor

Thanks. Im way ahead of you: http://www.diygokarts.com/vb/showthread.php?t=36067

But that is only one thing on the list....

---------- Post added at 03:25 PM ---------- Previous post was at 03:24 PM ----------

That thing is huge; looks almost street legal and like, complete with all the comforts of a 2017 Toyota.

Where's the fun in that?

If only it had AC.....

 

[Denny]

If you can't weld good weld lots!



Denny

 

[ShapeShifter]

I managed to get the drive clutch off the crank shaft using a puller. Shaft is not too bad.




---------- Post added at 02:44 PM ---------- Previous post was at 02:41 PM ----------

I thought I was going to have to use an easy-out to remove the broken bolt out of the crank shaft but when I dug in there to see what I was up against, it just came out in pieces. So I chased the threads with a tap and its all good.



---------- Post added at 02:48 PM ---------- Previous post was at 02:44 PM ----------

Getting the driven clutch off the jackshaft is harder than getting the driver off. I need to take it to a friends press. I also need some new 5/8" bearings.

 

[ShapeShifter]

We removed the blob of leprous weld by just parting it on either side. This also took off one of the bearing hangers.





The swingarm was sprung pretty badly and the cut ends did not line up after cutting out the bad weld so we cut the whole corner bend off so it could be clocked back into alignment. A plug was turned down on the lathe and stuck in the tube to re-locate that cut.




Then a replacement piece was cut from solid bar and shoulders were turned on each end to align the tubes. Also, the spring hanger on the blob-of-poo weld that was cut off was removed from that blob and reshaped to be reattached to the new replacement piece. This picture of those pieces is before it was aligned and welded straight.




We got everything aligned using the new axle in its bearing hangers to make sure there was no binding, then Dave did the welding. Dave always does an awesome job at welding!





This morning in the daylight we can see the difference between a correct weld and a weld of desperation. Dave is a funny guy as well as an excellent welder. I am thankful to have him as a friend.

 

[qtband]

Be careful when you press the jackshaft out of the driven. Take care of where you place the blocks underneath. They need to be as near to the shaft as possible and small enough not to hit the outer rim of the driven. The first one I did, I wound up with a bent pulley!

 

[ShapeShifter]

Be careful when you press the jackshaft out of the driven. Take care of where you place the blocks underneath. They need to be as near to the shaft as possible and small enough not to hit the outer rim of the driven. The first one I did, I wound up with a bent pulley!

It took some scrounging through scrap bins to find some blocks that went where they needed to go but it was done correctly. Thanks though!

 

[ShapeShifter]

The only way to get the belt to line up is to have the drive clutch spaced pretty far out. The crankshaft has a little more than half engagement which should be enough, but I am not happy with it.

Now I see why Manco used the yellow outboard spring with this jack shaft plate.



---------- Post added at 08:16 PM ---------- Previous post was at 08:04 PM ----------

https://goo.gl/photos/fuz8bwAE348y2xwm8

 

[ShapeShifter]

I passed a milestone this evening. I did a test drive in front of my house. At this point I have to decide the next steps. Should I just go abuse it, or should I completely strip it down to bare frame then paint and restore it.......

What would you do? https://goo.gl/photos/i19HqeTcewJAZB767

 

[andrecht]

I would abuse it first, find the weaknesses and attend to them. Normally it involves a bit of welding and drilling, bending and modifying.... and then strip it down and restore and paint.

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[bighead]

Look good. Nice job.

 

[chancer]

Do a cross cut on that "weld ball", It would be interesting to know haw bad it really was.
besides the obvious heat damage and brittleness of the weld.

Nice repair there too!

 

[ShapeShifter]

Thanks guys. I wish I could dampen the steering. This is my first gokart. Do they all steer like wrestling a drunken fat chick?

 

[gman3850]

Thanks guys. I wish I could dampen the steering. This is my first gokart. Do they all steer like wrestling a drunken fat chick?

not all but these karts do, ive had 3 and they all steel like crap, but the is due to there design. these should have had dual a arms not singles

 

[Whitetrashrocker]

You can try drilling a new hole and moving the drag link closer to the steering shaft. You lose travel, the amount the wheels will turn, but you will gain some leverage, making it easier to turn.

I looked at the first pic you posted, that's some mouse trap in the steering dept.

 

[ShapeShifter]

Yeah, the whole front end needs modification. Rack and pinion and upper arms are on the list....

 

[mindymogul]

Yeah, the whole front end needs modification. Rack and pinion and upper arms are on the list....

I'd know it'd look weird as **** but finding a old golf cart and harvesting the parts from that would work. Smooth steering w/ the gearbox and it's already designed to have lopsided steering. And I've seen some of the Yamaha G-series w/ dual control arms. The easiest ones to work with are the G1s. (Had a few of them).

As far as lights go check out this thread:
http://www.diygokarts.com/vb/showthread.php?t=32143