MrBracket, yep I am having fun, can't think of a better way to learn some welding skills!
Got a little more done and am ready to take it around the block, I live in a small neighborhood in a rural area with almost zero traffic and it's normal to see guys around here zipping around on dirt bikes and things, so my neighbors won't mind.
I welded on a pin for the brake return spring:
And here it is all hooked up. The chain will be replaced with a rod and clevis like on the brake rod. These manual disc calipers stick on when you apply the brake hard, I doubled up the return spring but will go with a single stronger one later.
I tacked the bolts to the pedals which makes them less floppy when mounted, and welded on pedal stops out of a bit of 3/4" square tube.
In case you couldn't tell, most of the parts I've been ordering are from AZUSA, they are reasonably priced and for the most part they have been working well on this frame. The throttle cable sheath was a bit too long so I slid the chrome end piece off and cut off about 2.5" with the Dremel, fits good now.
With the throttle cable fixed I needed a way to mount it. Every FW & Associates frame I've seen had tabs for the throttle but I couldn't see any evidence of them ever existing on mine.
Got tabs welded on and throttle cable installed. This setup is exactly like the AZUSA go karts.
There is no nice built-in way to connect a throttle cable to the Predator 79cc like there is on the 212cc. I removed the throttle lever and used a small piece of aluminum to connect it like this. Nothing modified and is adjustable.
Just have to put some gas and oil in it, zip tie the throttle cable out of the way, wrap the tach/hour meter around the plug wire and she's ready for a test ride!