New Manco super deuce owner

Papanicko57

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Hello from Colorado! I’m trying to build/fix a Manco Super Deuce I bought for cheap. The grands need to experience the fun I had a long time ago when I had a beat-up Odyssey fl250! The Manco looks much more usable if I can source spare parts. Thanks for the add, I’m looking forward to learning from the experts!
 

Papanicko57

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Thanks guys! I’ve poked around through the forums for advice. I don’t want to be the guy that jumps into a forum just to ask question! Here are some pictures as I’m working on it today. Pretty cool machine to me, but probably no big deal to many others. My current problem is sourcing the broken shaft. Everywhere I’ve checked is out of stock/obsolete item no longer available, even thought the website says it’s in stock. I’d really like to NOT replace the differential as I get started, but may need to do something. I’d surely appreciate any advice or experience.
 

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Grizzlymi

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Ask away man! Don't worry about that. That is what this forum is for. Just wait, someone with diff experience will chime in soon. (y)
 

Hellion

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Oh man, good to see an old Deuce. Those were a cut above the rest of the regular "karts" but it really is an early UTV/ATV.. I don't recall seeing too many of those around, like here on the forum, so maybe it is a big deal. A fairly rare bird to me anyway.

Good luck on the parts, man 😬. I'd say look for something you can adapt to fit but that is a fairly complex vehicle. If you really wanted to give your grands a taste of your youth I'd recommend a more regular, conventional kart that is easier to fix. Something like a Yerf-Dog, Murray Explorer, Manco Dingo or any similar variations on the theme with full suspension. One kart for each!

For reference, what are you looking for, is it:
10326-16 AXLE WELD 24.789 LG DANA
10327-16 AXLE WELD 23.539 LG DANA
...or something else? We got guys with good Gewgle-Fu skills

 

Hellion

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You might look into grafting-in the rear axle assembly from a trashed UTV or larger Chinese buggy or something.
 

Papanicko57

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Oh man, good to see an old Deuce. Those were a cut above the rest of the regular "karts" but it really is an early UTV/ATV.. I don't recall seeing too many of those around, like here on the forum, so maybe it is a big deal. A fairly rare bird to me anyway.

Good luck on the parts, man 😬. I'd say look for something you can adapt to fit but that is a fairly complex vehicle. If you really wanted to give your grands a taste of your youth I'd recommend a more regular, conventional kart that is easier to fix. Something like a Yerf-Dog, Murray Explorer, Manco Dingo or any similar variations on the theme with full suspension. One kart for each!

For reference, what are you looking for, is it:
10326-16 AXLE WELD 24.789 LG DANA
10327-16 AXLE WELD 23.539 LG DANA
...or something else? We got guys with good Gewgle-Fu skills

The broken part is the 10326-16, which corresponds to the right side looking from the rear. From what I’ve dug up, the parts are also American Landmaster Axle Shaft, Dana - 012SR140-2 Which is equivalent to 2-20862. Hammerhead, Landmaster, and Go karts R Us all list the part, but don’t have any. I could use some more Gewgle-fu skills myself!
 

Hellion

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Show us the whole shaft and the broken end. It looks like a clean break maybe. If it's just a plain shaft, maybe it can be fabricated somewheres....
 

Papanicko57

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You might look into grafting-in the rear axle assembly from a trashed UTV or larger Chinese buggy or something.
Yep, I’ve started looking into that option. It sure would be nice to just replace the axle, but that’s not looking like an option!
 

Papanicko57

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Show us the whole shaft and the broken end. It looks like a clean break maybe. If it's just a plain shaft, maybe it can be fabricated somewheres....
Here are a few more pics of it. You can kind of see where the pieces fit together. Have you had any success getting a broken shaft welded back together?
 

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Kartorbust

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One would have to know what kind of steel alloy it is, for the best success. Especially if it needs a preheat and post heat to prevent cracking. Would have to be ground down, both sides tapered, and carefully welded with a filler that is close to the same tensile strength of the axle.

Keeping it balanced and making sure that it doesn't warp, or get distorted will not be an easy task.
 

Papanicko57

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Wow. Crappy hollow spot in the axle.
And it broke right at the bearing.
Must have taken it off some sweet jumps.

View attachment 159308

What diameter is the axle? Could you use a regular axle and have a machine shop cut the splines?
Yep, broke at the bearing. The previous owner broke it while trying to jump over a ditch, as I understood the story. He was quite heavy, and apparently was going pretty fast 😄. It sounded like fun while it lasted.

I bought it cheap because I found several in-stock sources for the axle, but it turns out that inventory management isn’t what it used to be!
 

Papanicko57

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Wow. Crappy hollow spot in the axle.
And it broke right at the bearing.
Must have taken it off some sweet jumps.

View attachment 159308

What diameter is the axle? Could you use a regular axle and have a machine shop cut the splines?
I‘m almost positive the diameter is 1”, but I haven’t put a micrometer on it yet (mainly because I can’t find it!). I might have to try getting one machined, that’s probably easier than replacing the differential.
 

Denny

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Welcome! I just took a super deuce yesterday, it was painful. :cry: But this is a go-kart site not a colonoscopy site. So let’s forget about that. I’ve never seen replacement axles for the peerless axle anywhere. You’re probably going to have to adapt something else.
 

panchothedog

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From the pictures you've posted and the complexity of your axle, some custom machine shop work is probably your best bet. Slight change of direction here.
That thing is almost jeep like. Better suited for yourself. I'm with Hellion. If you want to give your Grandkids that go kart ( or Honda Odysseus ) experience, get a couple of 2 seat off road beater karts and fix them up. Parts are generic and plentiful, easy to work on, and being closer to the ground really multiplies the fun factor.
 

Hellion

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Yep, I’ve started looking into that option. It sure would be nice to just replace the axle, but that’s not looking like an option!

I wonder if it was discovered, while these buggies were still being made (or afterwards), that the axles were “defective” or the weak link that kept breaking all the time and that’s why there’s no spare parts. People bought up all the spares after a time. But then again the Deuce is long out of production and karts/buggies have a habit of sticking around instead of being sent to the crusher like automobiles. A perpetually needy patient.
 

Hellion

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Dammit, Pancho keeps making (monetary and practical) sense. Two seater karts are the way to go. Maybe it keeps more intensity in the activity because the passenger will always be jonesing for their turn. How many grandkids ya got?
 
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