Newbie going to start a go kart project

[frase]

hi all,
I'm based in the UK and I really want to start out on a go kart project, I don't really want to buy a rolling chassis or used kart as id much rather have the experience of building my own kart, so its a lot easier for me to repair.
info about my plan:

1. I want to use the single seat plan from the diygokarts main site
2. I would prefer a live axle, 2wd transmission
3. I would be planning to use the kart partly on tarmac, but mostly off road, not any seriously bumpy terrain, so I would plan on simply some chunky tyres, no suspension, to keep it simple.
4. i would be hoping on getting something like a honda gx160 or gx200.

i have a lot of questions to ask, sorry about the amount but I tried searching the forum and I couldn't find anything, I'm sure its there but the search just seems to bring up thousands of results! also, I want to be completely sure I make things right, I don't have a massive budget so don't want to have to redo things that I have done wrong!

so, the questions:

1. mild steel is good for the frame yes?
2. 1" or 25mm square box section will be right?
3. what kind of thickness should the box section be? (I'm using box section instead of round tubing as it's easier to weld)
4. what is the best way of fixing the wheels to the axles, and what are the best wheels to get? bearing in mind i am in the uk so a basic idea of the shape and size will be great if you dont know anywhere that posts to the uk.
5. are the honda clones safe to buy? and do all honda parts fit them?
6. i read somewhere that it is far cheaper to buy a bike brake and just a go kart disk, is that a bit complex to set up for a beginner or should i just go for one of the entire brake kits?
7. with the engine mounts, should i run extra bar across and bolt the engine onto those bars or weld on some sheet metal and bolt it to that?

thanks in advance, and sorry for the size of the post and amount of questions, but i really want to get this right!

 

[Doc Sprocket]

1) Yes.
2) Depends on frame design. A better supported frame can use smaller tube safely. A basic ladder frame should use larger tube.
3) Again, depends on frame design. Keep in mind that is it better to use larger tube with a thinner wall rather than smaller tube with a thick wall. Ends up being stronger, pound for pound. (or Kg as our case may be)
4) Depends on the axle and spindles you use. Hubs (and fixing methods) will vary according to the stock used
5) Clones are probably the most widely used engines by the DIY crowd. The cost and availability are "desirable", as is the fact that all the Honda goodies tend to fit. Bear in mind that you are NOT getting the quality you would with a genuine Honda (or Briggs, Tec, Subie, Victa, etc) Caveat Emptor
6) A beginner with some fabrication ability could get thru it, but for your first build you might want to avoid overcomplicating your mission.
7) Engine mount reinforcement is not a bad idea. Try angle iron. Sheet metal won'tdo much on it's own.

 

[frase]

thanks hugely for the replies, clears up a lot for me, just a couple more questions,
with the design found here: what thickness should i go for on the box section if i use 1" or 25mm?
is it alright to weld wheels to hubs if i cant get ones that bolt together?
at around the same price point, is it better to get a new honda clone or a used genuine honda engine in decent condition?
thanks again

 

[Doc Sprocket]

A new clone will still likely be cheaper than a good used Honda. But if budget allows, I'd get the Honda. Being used, it may need some work, but it will live forever ad be reliable as he// if properly maintained.

If you're going to use 1" tube for a basic ladder frame, your wall thickness should probably be in the 3mm range (a little north of 1/8").

 

[frase]

thanks hugely, just one more question for now, around how much steel should i get? with an extra 1/2 meter or so so i can get some welding practice on it before i go for the main build?


thanks

 

[Doc Sprocket]

Extra steel to practise on is a good idea. Also- if this is your first build, you should allow for mistakes. If you accidentally cut a member too short, you don't want to "lengthen" it again.

Total tubing length required will depend on your plans.

 

[frase]

these ones? http://www.diygokarts.com/images/in-use-move/framing-1.gif

just a rough estimate would be great,i just want to know how much i should get hold of on my first order, i can obviously order in more i just dont want the build to grind to a halt part way!
theres so many lengths that it just confuses me really, ill probably simplify that design a bit, so its mostly flat and no side pods
thanks

 

[Doc Sprocket]

Really depends on how you plan on altering the plans. 20' (7 meters?) is probably a good ballpark, but I urge you to sit down with a pencil and figure out what you really need.

 

[4wd_for_field]

something worth considering, but may not work for you.
if you check out my build (i'm a noob too) i bought a quad with a blown engine, originally for tires, but when i looked, i could use the full front axle including front suspension,hubs and brakes. all i had to do was split it and weld it on, and use my frame around that. considering you can often pick up a scrap quad for less than hubs wheels and off road tires, might work. heres a link to my build: http://www.diygokarts.com/vb/showthread.php?t=13059

 

[frase]

thanks, i will definitely check up on that, not many scrapyards around me but when i do get around to going to one there will probably be quads due to the amount of farm around me! your kart looks like a great build by the way