Josh.hymel
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So my son was given a razor dune buggy with a set of bad batteries and a bad motor. After discovering the cost of replacing the motor/batteries I decided to modify the cart to run from a 79cc predator. Along with a new motor I was going to put 15inch meaty mud tires on the back and 10 inch tires on the front. Also had to adjust the steering which was way far forward to something a bit more natural.
I cleared the room needed and fabbed what was needed to mount the engine. I had to machine the 3/4 inch hubs to 22mm and make a 5mm key shaft for the rear. Turned new spindle sleeves for the front wheels. Because the kart is so small and I was trying to not cut and modify the frame I opted to stick with the #25 chain and stock jackshafts, so I had to weld a #25 sprocket to a 5/8 clutch.
All worked out well. Until my son got to ride it. Although I was able to get a 6.2:1 final drive ratio on the chain drives, the 15inch wheels meant for very little hill climbing torque. This is when I decided to build a 2 speed gearbox.
I made my go karts 2 speed gearbox using Lovejoy couplings and nesting sprocket hubs into the coupling. Essentially making a "dog" type of clutch system similar to how boats engage gear. The final gear ratio are 5.2:1 and 10.8:1.
Here's some pics
Kens kart https://imgur.com/gallery/HO927
I cleared the room needed and fabbed what was needed to mount the engine. I had to machine the 3/4 inch hubs to 22mm and make a 5mm key shaft for the rear. Turned new spindle sleeves for the front wheels. Because the kart is so small and I was trying to not cut and modify the frame I opted to stick with the #25 chain and stock jackshafts, so I had to weld a #25 sprocket to a 5/8 clutch.
All worked out well. Until my son got to ride it. Although I was able to get a 6.2:1 final drive ratio on the chain drives, the 15inch wheels meant for very little hill climbing torque. This is when I decided to build a 2 speed gearbox.
I made my go karts 2 speed gearbox using Lovejoy couplings and nesting sprocket hubs into the coupling. Essentially making a "dog" type of clutch system similar to how boats engage gear. The final gear ratio are 5.2:1 and 10.8:1.
Here's some pics
Kens kart https://imgur.com/gallery/HO927
Attachments
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20160615_113318.jpg -
20170203_110137.jpg -
20180126_105516.jpg
