New project started

[modelengineer]

Ran the little go kart I made until it wore out both rear tyres and have decided to start on something bigger, which I can use on more rough terrain.

THE SIDEWINDER!

I've been wanting to build one of these for ages, so I started today. From 11:00 to 3:00 this is how far I got:

Nothing is welded yet as my garage floor is not completely flat. It took a while to get all the angles right. This helped a lot.

Hopefully when its finished it will look like this, but black (sorry about blurry photo)

I thought I would run a sort of 'build log' here, I have 2 weeks to do as much as I can and then it's back to school to study for final exams, so there will be a HUGE break right in the middle of construction but the thought that after I do the exams I will be able to finish and ride this thing should help keep me motivated.

P.S I aim to be working on this about 5 hours a day for the next 2 weeks. I will try to show my progress (or lack of) daily.

 

[crazycart]

Awesome, it looks like ya got alot to do. What engine do you plan on using? Im thinking 400cc+ sled or Bike engine would be perfect

 

[AutoMX]

well sled may involve too much cooling work, ATV would be a much more ideal donor and you get power to both wheels in the back. alternatively a bigger bike (600cc+) motor would send you flying but they can run alot of $$$

 

[sayre315]

that is gonna be AWSOME!!!

 

[modelengineer]

The manual recommends between 350cc and 650cc single cylinder bike engines, with the KLR-650 being (apparently) the best. I almost bought a yamaha XT-550 on ebay but it went slightly over my budget. Looking back I probably should have got it anyway.

Trying to do this kart without spending TOO much money, but shock absorbers and springs OMG. They are SOO expensive. To get them from Edge (they designed the buggy) is around $850AUD! I'll have to find some second hand bike shocks.

Going to try and weld up the bottom frame today, and maybe cut the metal for the top frame.

 

[gocartkid]

well sled may involve too much cooling work, ATV would be a much more ideal donor and you get power to both wheels in the back. alternatively a bigger bike (600cc+) motor would send you flying but they can run alot of $$$

If I were you I would buy an atv donor. You could use the engine, maybe sprocket/chain, wheels, and a bunch of other b.s. stuff like cables, etc. Then just sell the extra parts and you could probably end up with the atv parts for free. (I do this all the time, btw. I had a garden tractor that I was building and needed wheels and other misc parts, so I bought a cheap parts tractor then parted out what I didn't need. The tractor ended up being free and I even MADE money in that deal!).

 

[kibble]

That will be a pretty nice project! I was thinking of building something similar for my next kart project, but with two seats.

 

[modelengineer]

gocartkid that's basically what I'm trying to do, but with a road/trail bike because they are cheaper. If I could get a quad bike for cheap then it would be great because of the wheels AND quads usually have a reverse gear and electric start.

*TODAY*
had to get more welding rods in the morning and have almost welded the entire bottom frame together. Tomorrow should finish welding bottom frame and cut out the steel for the top frame.

 

[jr dragster T]

Why is all your metal already painted?

 

[modelengineer]

Tyler, it comes like that from the steel shop. I guess its to stop rust?

 

[jr dragster T]

Are you serious!!?? Around here all of our steel is covered in this black greasy soooty stuff that filthys your work gloves in a second.

 

[Kenny_McCormic]

Are you serious!!?? Around here all of our steel is covered in this black greasy soooty stuff that filthys your work gloves in a second.

same here

 

[oorgle]

check craigslist for a donor quad. thats what i did for my project. i bought a no name 150cc quad for $400 and stripped it. aside from wheels and engine you also get the sprocket, BRAKES (mine came with single rear disc and dual front drum), reverse if it has it but not all do (mine didn't ), lights, spindles and more odds and ends.

 

[AutoMX]

depending on what you feel like going for:

- major brand dirt bike or ATV = lots of $$$

- major brand street bike = less $$$, lots of crashed ones, but less torque and more clutch $$$ repairs

- chinese ATV, loads of them for about $550 new (125cc to 150cc) $800 for 250cc. obviously less reliability but ive heard good things about the motors themselves. the manual shift trannies are meh, and the stuff that really falls apart are the frames and suspension (which you wouldnt need anyway).
used ones are cheap. my 110cc X18 bike is still going good so its worth considering.

getting an ATV = brakes, which is VERY important in a bigger vehicle like what youre building. brakes from a street bike will take alot more work to adapt but its still doable.

 

[modelengineer]

*UPDATE*

Here is the fully welded bottom frame, complete

All parts for the top frame cut out, should be fully welded tomorrow or thursday morning

I'm pretty new at welding, but I thought that this weld looked pretty good

I think that I pretty much have to go with a large dirt/street bike because I need a 500-650cc engine. I am going to find out where the insurance companies auction off the written off bikes to hopefully get a good deal on one with an undamaged engine.
The plans specify disc brakes from a road/trail bike or small car to go on the rear axle. I am not fitting the front brakes because
a) very complicated
b) from people's feedback on the Edge forums I gather that on dirt you don't really use them
Trouble is, the price of a 650cc quad is much higher (usually) than a 650cc bike so I will probably end up with a trail bike.

Thanks all for the replies.

 

[kibble]

Wow dude! You're moving right along with that thing!

BTW that weld does not look bad at all!

 

[Kenny_McCormic]

Nice welds, they are perfect. What welder did you use?

 

[modelengineer]

Hehe, keep in mind that I pretty much found the best weld on the whole thing and got a pic

All welding is done with a 140AMP arc/stick welder - a buzzbox, and an autodarkening helmet. Those helmets are a must!
Not sure of the brand of the welder, will post in next update.
Oh, and 2.6mm 6013 rods. The tube that these two frames are made out of is 40mm x 40mm x 2mm. which is about 1 9/16 in square with 5/64 wall thickness.

 

[Zippy K99]

Thats going to be wayyyy sweeeeeeeeeeeeet!!!!!!!!!!!!!!!

 

[oorgle]

gotta admit i am really interested in seeing how this buggy turns out. for my next project after my current one i was thinking of either buying plans off theo on gorkartforums or getting some plans from edge. I'm just not sure of the edge buggy's have the clearance i will be looking for.