Seems like a monsterous task...

[shawnstock]

Might as well start here... Have two daughters (13 & 10) who just got their first experience with a go kart a couple months ago and they loved it. I told one of my fellow workers that I would love to have a go kart for them.

Next thing I know, he comes to work with this!

And a pile of miss matched wheels...

I'm a tinkerer, but never thought of taking on a project like this. I did find out it is (was) a BDM F1-265 and even found diagram's and part list for it... But...

I,m just trying to figure out where to start and I guess I'll learn as I go... (Next time I will be more specific with my co-worker...)

Any help or guidance will be much appreciated...

 

[souperman000]

For starters, its good you found the model. It looks like a dead axle set up (one wheel drive). You need to put that sprocket and brake drum (left hand side of the picture) on the drive wheel side.

If you are looking for a motor, you can't go wrong with the Harbor Freight Predator.

Welcome to the forum! Keep on askin' questions too!

 

[Half-breeder]

1- Get it visually sound(ensure everything is 'straight' n 'true').
2- Get together essential parts together(motor,clutch, brakes, bearings, unkinked chain, etc.).
3- Install parts ensuring tightnesses n alignments(all nuts/bolts tight n sprockets/chain inline).
4- Test run(reensure nothing 'coming' loose/binding).
5- Finalize safety, appearance... enjoy!(get safety gear, flag, reflectors, maybe a horn?... maybe paint it?).
6- After kids get used to driving it...UPGRADE!!! Lol(live axle, larger wheels/sprocket/disk brakes, maybe steering?).

HF 212cc 6.5hp clone would be my choice in a first motor...120$(read the directions... theres a "break-in" method/period).

Gears Id gear low(for kids)... Maybe a 10T clutch n 60T axle? Or if your rear wheels have enough diameter you could go w/ a 72T at axle... Little top speed... More than enough torque/power!

But to 'start' w/?... Id find/make a place to plop your butt as you evaluate you next step(Ive spent HOURS just sitting in my kart... thinking of my next step of upgrading! Lol.

For YOUR kart Id remember these key words/phrases...
Dead-axle-(limited to 1 wheel drive)
Band-brakes-(brakes that use a clutch type housing as a braking surface by contration of a 'band'.
Wheel bearings-(tend to wear dependant on abunch of environments/reasons.

After you get her to 'factory' standards... Thats the time to 'fabricate' .... IMO.

...And welcome to the forum. Keep the pic n questions commin... someone'll be able to eventually answer your questions(w/ the right enough info provided).

 

[OzFab]

Well, it's not a bad place to start, it looks ok from here & most of the essential parts are there...

So, what, he just gave it to you?

These two guys have it pretty much covered in terms of a "to do list" so I won't digress... yet

Welcome to the forum

 

[landuse]

Gears Id gear low(for kids)... Maybe a 10T clutch n 60T axle? Or if your rear wheels have enough diameter you could go w/ a 72T at axle... Little top speed... More than enough torque/power!

A 6:1 ratio is not low. It is actually on the borderline of being high. A low ratio would be 7:1 or 9:1. I would go this route if you want some torque and less speed.

 

[Half-breeder]

A 6:1 ratio is not low. It is actually on the borderline of being high. A low ratio would be 7:1 or 9:1. I would go this route if you want some torque and less speed.

...and w/out a JShaft... 'how' would he/I go bout doing 'said' low ratio?... inquiring minds wanna know... HELL, I wanna know, for 'my' daughters dead axle kart w/out a JShaft n 10" wheels... OH... and I have no 'plans' on putting in a JShaft, on hers, or rock climbing w/ it, cuz a single wheel on grass bites no matter how you look at it, and add a 'hill' to it(which I 'live' on... might as well breakout the lawn seed, cuz your GONNA be diggin some earth. Torque slows things down yes... but....so does that throttle limiter screw on an HF clone and a less push on the gas pedal works too. Besides... who wants a kart that you can 'crawl' faster than?...might as well getta riding lawnmower n kill 2 birds w/ 1 stone, in that case... IMO, karts are 'fun' cause they move you 'faster' than you can on foot...w/ lil-no excursion... in 'kids'(like myself) it's the adrenalin that makes a kart 'fun'... the fact that you're sitting down, n moving...and the further you push the peddle the faster you go until either you get too scared to push it any further... OR the gearing limits your 'further' growing 'fun'...but it 4:30am and Im rambbling...

So... w/out buying/fabricating(cuz dont look like shawn has a JShaft either)/installing a JShaft... how 'would' someone go bouts attaining those ratios? Unless your talking an 8T clutch n a 60T axle would get up to 14mph on 10's... I dont know... what did 'you' have in-mind?

REMEMBER: He wanted to know where to start(so he probably is a beginner like myself and 'others' that may read this thread) I dont know 'too' many ppl that can/able to build the 'perfect' kart... w/out 'learning' from the beginning/most 'basic' concept...first, through trial n error. Hell, 2mths ago I didnt even know what a 'band-brake' or a 'dead-axle' was, let along they existed...now(after learning... from the 'novice'/beginner stage first) Im fusing a separate rearend assembly off another kart to my 'show' kart as an 'upgrade'(NOT the perfect upgrade mind you... but an upgrade none the less)...

 

[landuse]

...and w/out a JShaft... 'how' would he/I go bout doing 'said' low ratio?... inquiring minds wanna know... HELL, I wanna know, for 'my' daughters dead axle kart w/out a JShaft n 10" wheels... OH... and I have no 'plans' on putting in a JShaft, on hers.....

Short answer? You don't.

With a setup where you go from your clutch to the axle sprocket, you are limited in the gear ratio that you can achieve. It is limited by the number of teeth you can get on your clutch, as well as the diameter of your tyres. I say tyre diameter, cos this is what gives you clearance between the ground and your axle sprocket.

Realistically, most karts cannot be geared lower than about 7:1 with a direct clutch to axle setup. Go any lower, and your axle sprocket is going to be dragging through the ground. If you want to gear lower, the only option is to get a jackshaft. Increasing the tyre size to get a larger axle sprocket is counterproductive, as the one pretty much cancels out the effects of the other. Getting larger tyres is sort of like gearing higher

If you decide to get a TC, you are able to gear slightly higher than if you use a centrifugal clutch. This is due to the variable ratios that the TC gives you

Let me know if I haven't explained things clear enough

 

[Half-breeder]

nope... seems clear to me... just hope its as clear to everyone else as well. ty.

 

[OzFab]

...But wait, there's more:

....so does that throttle limiter screw on an HF clone and a less push on the gas pedal works too.

Unfortunately, again, the answer is no...

Limiting the throttle movement will only shorten the life of a cent clutch; a clutch will only lock at around 2200rpm, lower than that, it's slipping. By adjusting the throttle stop screw you reduce the amount the engine will rev &, in turn, reduce the chance of the clutch locking, shortening its life...

 

[landuse]

...But wait, there's more:



Unfortunately, again, the answer is no...

Limiting the throttle movement will only shorten the life of a cent clutch; a clutch will only lock at around 2200rpm, lower than that, it's slipping. By adjusting the throttle stop screw you reduce the amount the engine will rev &, in turn, reduce the chance of the clutch locking, shortening its life...

Dang! I was going to say that but forgot all about it writing all the other stuff. Thanks Tony!

NEVER, EVER try and limit the throttle to reduce speed!! The only safe way to do it is through GEARING

 

[Half-breeder]

Hmm... didnt know that... GOOD bit of info from yous guys. Tyty. Got me thinkin a cent clutch is 'not' the way togo... for me... But im not wantin to spend alot on a TC... Wonder if HF makes/has a good one? If not, probly wont b till income tax time b4 I can get one... sign.

 

[OzFab]

Dang! I was going to say that but forgot all about it writing all the other stuff. Thanks Tony!

Don't sweat it, I got your back We can't always think of everything

 

[shawnstock]

Love the feed-back guys... Like the idea of just getting it together and working first, then start modifying. Am going to work at getting it back close to it's original factory build, with only minor adjustments do to parts.

Have started making my list!

First off, I need to get it home, where I can strip it down and check all the parts that are currently on it. I did notice that the rear axle studs are bend back a bit and I will have to straighten them and the front wheels angle out (Hope just a minor linkage adjustment there...if all the linkage is good.) And then give the frame a paint job... nothing spectacular, just probably a good coat of rust-o-lium for right now...

I have the time... and enough patience... just need to keep the $ factor down as much as I can for right now...

 

[Half-breeder]

Love the feed-back guys... Like the idea of just getting it together and working first, then start modifying. Am going to work at getting it back close to it's original factory build, with only minor adjustments do to parts.

I had a feeling that was what you were gonna plan on doing...

I have only spent 250$ on my kart as is 'now'. Only new parts were motor, clutch and band-brake. Other things like the front rims I got used off some guy down the road, seat I made...
~~BEFORE~~

~~CURRENT~~

Click here for buildup video

Keep us updated w/ pics n detail procedures... their always welcome.

 

[shawnstock]

UL stopped by my production to do an inspection... (Steve) saw the frame and asked our quality guy about it... Later Steve swung by my desk and told me he had an older 5HP horizontal shaft engine that worked and he would throw it into his car and next time he was near, he would drop it off... He is just happy to get rid of it...

I was looking for a 6.5HP, but even if this one doesn't end up on my Kart, it will give me a chance to start learning small engines... Awesome how things seem to be working...

Mayhaps, I need to leave it at work a few more weeks... may end up with clutch, chain, seats, and wheels...

Naw... need it here at home, so i can get busy!...

 

[OzFab]

Good to hear you intend to "have a go at it" Be sure to start a build thread with lots of pics...

A 5hp should be ok on it, you can always upgrade later but, it'll help get it going for now.

As for the wheels, probably just an adjustment needed, we can sort that when you get to it...