Rigid GX160 > GX390 Clone Off-Road Resto-Mod

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Sleepy122CID

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In the past couple of days I have made a lot of progress. Final jackshaft mount welded up, chain sized, belt mounted, pedals and linkages mounted (BTW, anyone know where to get stronger pedal return springs?). Figured out the throttle linkage. Got it about ready to run.
 
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Lamest looking thing I've put together with the scraps around the garage. Should be strong enough though. The upper part of the bracket (actually one of the original seat mounts that I had cut off) is actually riding down that bottom piece of metal a bit (overlapped), so I was able to make the middle weld you see, and another one further up on the inside.



Got these rods back in. I tried to stretch the springs out to make the pedal stiffer, but it didn't help that much. I found some springs at mcmaster carr. Any suggestions for how many pounds of pressure might be a good amount of resistance for the pedals?



Belt on...



I ended up cutting those retaining clips off the control rod ends, drilling the rods, and cotter pinning them:



Chain on... tires on... Any tire pressure suggestions? The fronts have tubes. Right now they are all at 10 psi.





 
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Jasoninsane123 said:
They come stock with the return springs so you don't have to rig up the thorttle like most people have to with a spring thats why i love my kart makes the job easier
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Yeah I guess I misunderstood. The springs were already there, I was just asking about using stronger ones or extra ones...
 
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devino246 said:
How are the bearings on that jackshaft. I have the same ones & they seem kinda cheap
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They seem fine. I got it running, and this thing is so torquey! After I double bolted every jackshaft mount (so the shaft would quit slipping), and ziptied around the axle sprocket to keep the key from rattling out the thing feels great! I want to try and get some video up within the next few days. It pull started on the first try (like I guess it should have - it is a new engine). I may end up removing the starter for now because it is easy enough to recoil start. This CVT setup is outstanding... I don't understand why anyone wouldn't use one!

I still need to make rear fenders, do something with the steering (the LF tie rod end [ball joint] popped off), and this thing will be ready for powder coat.
 
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Update - this weekend I will be working on some sort of weight holder for the front end of the kart. Right now it is so light that it just wants to understeer like crazy - maybe on a hard surface it would be a different story. Also, one of the tie rod ends broke. I made a little temporary fix for it, but the new tie rods are back ordered for a couple of weeks.
 
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sideways said:
Now you just need a cute lil' exhaust :devil2:.

Hayden
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That's what the black box is on the left side =P

The stainless tubing is already on the way. I'll have to try and hand cut a flange I guess as well =/. Not sure how it is going to turn out, for I don't plan on having any bent tubing. I will be making all of the bends with pie cuts only (mainly for more practice welding tubing).

I have an ARC flywheel that I'll probably wait to put in when I have everything torn apart for powder coat. It is getting harder to find time to work on this project.
 
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Today I made a mental design of my exhaust =P, got the new steering wheel on (which feels about 75% better for an adult driver - it is wider and sits further away than the other one), put the "cage" back on, and got some weight on the front end to help get enough traction to steer =) ...

No, I didn't steal the Dora blanket from my daughter. I don't even have kids but found that thing in the garage!







The fit up:









It felt much better with the 25lb plate, but it could still use some more - possibly as much as another 25lb plate or more.





I still need to figure out the rear fenders, build the exhaust (hopefully to my mental blueprint), and figure out a way to keep the plates mounted securely. The top collar ended up stripping from the vibration after I tightened it enough to hold the plate securely. I am going to try two collars on top and see if that helps.
 
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I ended up using a collar with a set screw on top of the internally threaded collar, and it seemed to help hold the weight from vibrating much better. Today my exhaust piping arrived, so hopefully my next update will include the beginning of the exhaust assembly...
 
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theo

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To bolt your weights to the frame. The flange will be much better then a collar.
 
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theo said:
To bolt your weights to the frame. The flange will be much better then a collar.
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Oh... yes that could work. I have essentially the same design though - the collars are threaded like the flange I believe you are describing has. The threaded collar was loosening from the vibration, but the collar with the set screw on top of the threaded collar seems to be doing the trick.
 
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modelengineer

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That's a great looking kart, but I'm a bit concerned about this weld:



Where that disc is welded to the frame, the weld looks like it's just sitting on the metal with no penetration. I'd grind it out and do it again. Better than having it fail when you're out having fun.
 
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The very top weld in the picture? Where the bearing holder is welded together (sitting on top of the brace)?
 
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