Rigid GX160 > GX390 Clone Off-Road Resto-Mod

[Sleepy122CID]

Rigid GX390 Clone Off-Road Resto-Mod

Some of you may have seen my thread before I picked up this kart and some of my beginner karting questions. I've decided it is already time to start a build thread because it should be fairly exciting and perhaps I can get some tips as I go along instead of starting new threads when I can't find info for even basic information. Feel free to offer suggestions and constructive criticism!

For those who have not seen my previous threads - I picked up this kart about a week ago from a young man on Craigslist. Even though there is obviously rust under his paint job, I feel like I got a fair price on the kart. If I had fabricated my own chassis it would've taken me months to complete. A lot of the things I was planning for my build were already done on this chassis, but time will tell if they will actually be usable or if I'll have to redo them anyway.

I only have some pictures from when I picked it up so far, but with parts coming in this week I should have some new pictures from the fabrication process by next weekend. Since these pictures I have picked up a 13hp engine from Harbor Freight (I was going to put more money into the GX160 then I think it was worth right now just to get it running right), removed the roll cage portion of the chassis to actually fit the engine in there, and I am awaiting a Comet 40 series torque converter setup, jackshaft kit, tires, chain and sprocket, and a few other minor things to get the job started.

After I finish mocking everything up and get this thing moving under its own power I will be stripping it down to sandblast everything to good metal and powder coat (which will not cost me much, for I will do it all myself). Right now I'm thinking about doing a wrinkle finish on most everything, for I think the metal will be pretty pitted after all the rust is gone and I don't want to spend the time smoothing everything out perfectly. I'm thinking about wrinkle black on the lower portion of the chassis and everything I will be touching (pedals, etc), possibly a wrinkle blue on the cage portion of the chassis, and perhaps a gloss gold on the wheels - I'm still open to suggestions on these colors though.

 

[manco606]

i think you should do the main frame black and everything else the gold, and have the petals and little things gold as well , do you plan on modifying the frame at all e.g. adding suspension? oh, and that seat looks mighty comfy

 

[Sleepy122CID]

I'll have to see how pitted the metal actually is after media blasting. I'm assuming the worst. That is why I'm already planning to use textured finishes - we'll see =). I have a bucket seat on the way heh. The only part of the cage I really plan on modifying right now is the rear section to clear the engine if necessary. Oh yeah, I'm going to keep it rigid. The little track I plan on building on my property will be pretty smooth, and I don't want to put the money into suspension... yet heh.

 

[Blazkowiez]

Just as a heads up, on the drive/driven clutch on your torque converter, I've been able to clean clutches looking that bad using a pneumatic tool and a 3M wheel, it turns out amazing.

 

[Sleepy122CID]

Just as a heads up, on the drive/driven clutch on your torque converter, I've been able to clean clutches looking that bad using a pneumatic tool and a 3M wheel, it turns out amazing.

Thank you for that tip. I was thinking about trying something like that, but I haven't ever been inside one of those so I wasn't sure exactly how it worked or if I could do anything with it. I will need the 40 series setup (from what I've read) anyway for the "big block" I'm putting on there, but I have already ordered a gasket kit and a few other little things for that GX160 to try and get it in a usable condition either for a future build or to sell to try and get a little bit of my money back. I will try and get that 30 series setup working as well. I already got a belt for it =).

 

[Sleepy122CID]

Just a few pictures with the engine resting where it may one day be. I couldn't quite fit it in there with the cage on . Today I received a 3/4" jackshaft kit in #40 chain in the mail.

 

[Jasoninsane123]

Dang looks like i wont be getting the 13hp motor unless i mod the back part of the cage i love my rollcage because it saved my life once....looks like if you removed the muffler and add a straight pipe it would fit with the cage on or just remove the cover that goes over the muffler

 

[Sleepy122CID]

Dang looks like i wont be getting the 13hp motor unless i mod the back part of the cage i love my rollcage because it saved my life once....looks like if you removed the muffler and add a straight pipe it would fit with the cage on or just remove the cover that goes over the muffler

Yeah I was thinking about modifying the exhaust or just barely modifying the cage. The picture with the engine sitting in there crooked was after I just tried to slip the engine in from the side though. If I install the engine first it may clear the cage just fine as is.

 

[Jasoninsane123]

Yeah I was thinking about modifying the exhaust or just barely modifying the cage. The picture with the engine sitting in there crooked was after I just tried to slip the engine in from the side though. If I install the engine first it may clear the cage just fine as is.

i hope so if not its not alot of work to make it fit with the cage on maybe a little muscle to bend it alittle

 

[Sleepy122CID]

i hope so if not its not alot of work to make it fit with the cage on maybe a little muscle to bend it alittle

Yeah it would make it easy, but it wouldn't be a huge deal to modify the cage or relocate the motor mount - I own a welder . I'm already planning on doing a good bit of welding for the jackshaft mounts.

 

[Jasoninsane123]

I don't own a welder but have done alittle welding

 

[devino246]

I vote custom exhaust

 

[Jasoninsane123]

I vote custom exhaust

same might add a little more hp and sound alot better

 

[Sleepy122CID]

I vote custom exhaust

I've been thinking really hard about it, but I'm going to make myself drive it stock before I start modifying it. I want to keep it fairly quiet. That is the main reason I went with a 4 stroke engine . I've seen some small mufflers that some of these kart shops are selling online. Has anyone had any experience with them? Are they pretty free-flowing, or would it render the custom exhaust pointless?

 

[Fast Eddie]

Looks like a fun project Sleepy! That current TC won't fit the 13HP? Bummer. Save the motor/TC assy for another project! Good luck.

 

[Sleepy122CID]

Today I received a few tires, new u-bolts/nuts, a bucket seat, and a few other miscellaneous items...

 

[devino246]

If you ran a custom exhaust your engine would probably fit.

 

[Sleepy122CID]

Today I received an adapter mount for the "big block," another tire, and the 40 series drive pulley! Tomorrow I will get some pictures so I can get some help with setting this thing up. Tomorrow my 60 tooth axle sprocket should be here. I'd like to get everything set up this weekend so I can measure and order the drive belt. I'm not sure yet, but it looks like the best idea may be to mount the jackshaft in front of the engine... Would it be ok to slot some jackshaft mounts to adjust chain tension? The motor mount will be slotted as well to adjust belt tension. Any thoughts?

 

[Sleepy122CID]

New realization today: I have a differential...

 

[freakboy]

horay for one wheel wonder!