Metal Shop Kart Pair

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BaselessEarth12

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So! Quick update: freezing rain + 3 more inches of snow = testing grounds full of suck. But, the fuel lines are set, throttle cable's been hooked up, auxiliary fan switch has been installed (but not wired), ignition (shockingly!) wired up, measurements for seat base taken, alignment fiddled with, and front cowling interior installed. A lot of work has been done, indeed!
 
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BaselessEarth12

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Good news, everyone! Engine is installed, belt has been tightened properly, choke cable routed, discovered seat frame damage has been repaired, exhaust pipe has been welded (but not installed, still waiting on connectors), fuel lines are in place, carburetor has been cleaned, and most of the basic wiring has been completed! I should hopefully have some pictures up by the end of the day. And, if things go well, I might just be able to have a little test drive later today...
 
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BaselessEarth12

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More progress today: Shifter, fuel tank mounting tab, "fancy" wooden trim, "D" ring recovery point, got the theoretical seat mounting brackets laid out, and replaced the "Big One" (a bolt that was roughly twice as long as it needed to be, with a piece of generic steel pipe used as a spacer). Sadly did not get a chance to test fire the engine today :(... But, I was able to upload some pics from yesterday!
 

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BaselessEarth12

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Good news, everyone! Not only does the engine run, but it runs smoothly! The only downside is that the clutch is stuck, so I am going to have to dowse it in WD-40 tomorrow to sit over the vacation of two and a half weeks. Will more than likely get some much needed parts for it, too, so that'll be nice. SO! Plans for the not too distant future: free the clutch, install the seats, add a latch to the shifter to keep it in neutral from the vibrations, test drive it (FINALLY!!), record straight-piped roar, build the front sub frame and possibly some A-arms, then lastly new wheels and tires.
 

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BaselessEarth12

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Got the clutch off, cleaned the shaft, lubed it, put it back on, fired the engine, hit the throttle, the clutch compressed the way it was supposed to, and it did NOT open back up all the way!
 
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BaselessEarth12

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A couple good whacks with a hammer, and the clutch was fixed! Once I get the seat hinges all welded and bolted into place, it will be all set for her maiden voyage! Next week. Because the weather has been really really cruddy...
 
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BaselessEarth12

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Good news, everyone! I have figured out how I am going to set up the exhaust, and have the seat hinges prepped for welding and boring. The hinges are meant for a shed door, so have holes only big enough for a wood screw (roughly 1/8"), and I am going to "bore them out" to 1/4" then drill holes through the bed frame and the firewall to hold them together, AND reinforce the bed frame at the front. Doing so will also keep the shifter from moving too much while shifting. Then, once the seats and exhaust are squared away, it's on to the front suspension! My plans are relatively simpe: 2 post arms with 3 pivots each, a 2 pivot end block, and the stock spindle brackets welded onto them. Credit for the arm design idea goes to '69 baja (original forum: http://www.diygokarts.com/vb/showthread.php?t=7633, pictures 1-4)
and credit for my subframe idea goes to Garified (original forum: http://www.diygokarts.com/vb/showthread.php?t=9689, picture 5).
 

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Denny

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Yes you should be able to put the stock starter/generator back on with just a simple clutch change ( put the clutch off of the original engine on the snowmobile engine and make new brackets).

Denny
 
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BaselessEarth12

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Good news, everyone! Yesterday I scored 2/3 of a 2005 Honda TRX450r ATV front end! Right upper/lower control arms and steering knuckle, and left arm (wasn't told if it was upper or lower, just got a call from my grandfather about it). Today, I am hoping to get the seats installed and the exhaust finished. If all goes well, I will be testing it by the end of the day or thursday! So, once I get to the front end, any suggestions for shocks? Should I use the stock EZGO hubs on the TRX450r knuckles, or use some Honda hubs with front brakes? Either way, it's going to be pretty sweet when she's done!
 
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BaselessEarth12

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XD Now if only I could get a free exhaust setup... The guy I had weld my exhaust (who is the same "genius" I mentioned back on page 2 that burnt the bolt off the spring), while I was trying to figure out wiring and measurements for future front subframe, messed up BIG in the process. He marked the 4 pieces, but mixed them up, so instead of 1+1 and 2+2 it was 2+1 and 1+2, which means that the custom header doesn't fit. So, a big question: is it possible to flip the cylinder head (rotate it 180°), and how much work would be involved?
 
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BaselessEarth12

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Got the cylinder heads rotated! Now all I need is a complete gasket set...
 

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Desertduler

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BaselessEarth12 said:
Got the cylinder heads rotated! Now all I need is a complete gasket set...
Click to expand...

Say, did you turn the pistons around also? because the end gaps of the piston rings MUST be located in the cylinder as they were before or the end gaps can protrude out of the exhaust ports and you will have a huge problem. Also what about the transfer ports in relation to the crankcase? is the crankcase porting symmetrical as to not make a difference of flow?
 
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