Think it'll work?

[turbojimmy]

So I picked up this old kart from a guy along the roadside. It came with the new-ish Honda clone 11HP engine, but no means of getting the 11 HP to the tires. So then things begin to snowball, because I'm impatient and impulsive.

I got to poking around the 'Net and read about centrifugal clutches and torque converters. Torque converters seemed to be the way to go. So I got a 40-series setup from fleeceBay.

But now I need a jackshaft. Ordered a jackshaft kit.

But I have limited space to weld the jackshaft bearing retainers. So I got a jackshaft/engine mount.

Now it looks a little ugly, but I think it will work once it's all bolted down. Of course now the throttle cable is too short (anyone need a 61" long, brand-new Manco-type throttle cable? I got one I can't use).

I'm waiting on a belt now to see if it will work. The engine is a little big for the mounting plate, but I can make it work.

Did I say snowball? I got looking at my new acquisition and decided I wanted a rollbar. So I got to looking at Craigslist. Found a Manco 485-13 carcass for $50 that I can swap everything over to. Gonna clean it up and paint it first.

I have a brand new MIG welder and oxy torch that have been sitting for years (had aspirations of learning to weld). I think now is the time to dust them off and try to customize that Manco frame.

Wish me luck!

 

[turbojimmy]

So today I picked up the oxy/acetylene torch and mig welder from my dad's house. It's been 3 years since we bought it (and never used it), but I'd SWEAR I bought a tank of argon gas back then. Couldn't find it. But both the oxy and acetylene tanks were full.

First time with the torch (note to self: buy gloves). I was able to cut oval-shaped holes for mounting the engine. The heat buckled the mounting plate a bit, but it will be fine. It also set it on fire due to years of oil accumulation. But that's just part of the fun.

Once I dig up the argon tank I'll try the MIG welder. I want to get that Manco kart mobile!!

Oh yeah - big problem here in NJ is where to ride. I had some firewood dropped off today (yes, it's July but it needs to season) and the firewood guy noticed the kart in the driveway. He asked where I was gonna ride it. I said I dunno yet. He said "bring it to my farm!!". Awesome. He's got a ginormous farm where we can tear stuff up. Problem solved! Now I gotta get it working!

 

[robbie]

Sounds like you're the kind of guy who likes to jump in and get things done, so I don't want to fill your head with too much nonsense. I just wanted to say that you'll make better mounting holes with a drill, a center punch, and an assortment of bits. The torch makes a huge mess. Measure the centers of all the holes, transfer the locations to your part, and center punch each one of them. Then drill with a smallish bit, then enlarge to the right size. If one of them is a little bit out of place, enlarge it until the bolt will go through.

 

[turbojimmy]

Sounds like you're the kind of guy who likes to jump in and get things done, so I don't want to fill your head with too much nonsense. I just wanted to say that you'll make better mounting holes with a drill, a center punch, and an assortment of bits. The torch makes a huge mess. Measure the centers of all the holes, transfer the locations to your part, and center punch each one of them. Then drill with a smallish bit, then enlarge to the right size. If one of them is a little bit out of place, enlarge it until the bolt will go through.

You're right. But....

I had made a template out of a piece of paper and taped it to the mounting plate. I drilled and removed the template. It wasn't square with the drive sprocket. So, drilled holes next to the holes I drilled and cut the gap out with the torch to make egg-shaped mounting holes. Now I can rotate the plate any way I want. And yes, the torch made a huge mess But it got the job done, kinda.

 

[Kent]

Jimmy your an animal.............Great post.........Great Pic's

Pic's are very helpful to nebbies like me

Good luck with your Kart...........Kent

 

[turbojimmy]

Eureka!

It works! The chain is pretty tight, but it was either too loose or too tight. I have very limited adjustment since I had to customize both the cart mounting plate and the jackshaft mounting plate because of the size of the engine.

I don't know how long it will last, but it seems solid right now.

 

[turbojimmy]

Vid of my 6' 1" brother jammed into the thing. It pulls him and my son around nicely.

http://www.youtube.com/watch?v=3Phk4ohRUYk

 

[turbojimmy]

Okay, I broke it already.

Had been driving around with a 14T sprocket on the jackshaft. Switched to a 10T. The torque and acceleration was amazing, and also bent the jackshaft. I'll have to install another bearing retainer at the end of the shaft for additional stability.

It was great for the 5 minutes it lasted. Trial and error.....

 

[r_chez_08]

Okay, I broke it already.
It was great for the 5 minutes it lasted. Trial and error.....

Reminds me of my kart :L

 

[turbojimmy]

Other then heat distortion, If you know how to use a torch and have alot of experience cutting slots with a torch is no problem and very clean.

The plate did distort from the heat, but otherwise the holes weren't too bad. The "mess" part was the soot from the acetylene flame. It was my first time using a torch, so I don't know if I had it adjusted right or not. The instructions came with a flame tip guide for welding, but not for the cutting tip. It was like a freakin' flamethrower. Said to heat up the work with the acetylene, and then hit the O2 button to cut. Seemed to work okay, but left soot all over the place.

I need to weld up a bearing retainer for the end of that jackshaft - that'll be my first use of the mig welder.

Once I get this thing running right I'll move on to the Manco cart. It looks like everything will easily swap over except for the rear axle. It has a differential and therefore mounts differently than the stock, solid Manco axle did.

Jim

 

[turbojimmy]

No no, You light the torch on acetelyn, Add more fuel till the black soot goes away an then add oxygen till you get a nice neutral flame with the cones and no feathers. Shouldnt sound like its hissing either. You heat the materiel with this neutral flame till you see a small pool of molten steel THEN you push and hold the cutting handle. Shouldnt be any soot at all.

Thanks! The instructions weren't clear. There are 2 O2 knobs. It said to leave one all the way open, but I didn't mess with the other. I guess the other one would give me that nice neutral flame. I'll have to goof around with it some more.

 

[Chris T.]

Open the O2 adjustment on the torch handle to FULL, then use your adjuster on the cutter body to adjust your O2. Also there is no goofing with torches, one wrong move and you can have a very serious problem on your hands.

One thing I would recommend getting is a pair of flash-back arrestors if your torch doesn't have them built in already.

 

[Kenny_McCormic]

You might want to tear down that diff and if it is in less than perfect shape, weld the spider gears to the pin as a crude "lincoln locker". They tend to come apart in normal mower use, let alone abusive kart applications.

 

[turbojimmy]

Open the O2 adjustment on the torch handle to FULL, then use your adjuster on the cutter body to adjust your O2. Also there is no goofing with torches, one wrong move and you can have a very serious problem on your hands.

One thing I would recommend getting is a pair of flash-back arrestors if your torch doesn't have them built in already.

Thanks. I'll look into that.

 

[turbojimmy]

You might want to tear down that diff and if it is in less than perfect shape, weld the spider gears to the pin as a crude "lincoln locker". They tend to come apart in normal mower use, let alone abusive kart applications.

I'm thinking of putting a solid axle arrangement onto the Manco cart that I got instead of moving that diff over to it. The parts are too expensive, though, so I'm looking for another frame with the axle and brakes already on it. Stumbled across a few already, but it's frustrating when people post stuff for sale and then don't return calls or e-mails. I'll come up with something soon.

In the meantime, the new jackshaft should be in this week and I'll be back in business on the old kart.

Jim

 

[turbojimmy]

I put a pair of flashback arrestors on my torch, got some filler rod and bought some argon gas for the MIG welder. I thought I'd try my hand at cutting and welding with the torch first.

On Saturday, my first attempt at cutting resulted in setting my hair on fire. Seems that if you hit the oxygen lever before the metal is properly heated, you get a shower of molten steel and sparks. I put everything away and went in the house.

On Sunday, I watched some YouTube videos about cutting and welding with a torch. I got the torch back out and successfully made some decent cuts. Now on to welding. Using a flat piece of steel, I made a bracket to which I affixed the bearing retainer to support the end of the jackshaft (remember it kept bending from the torque?).

It's not bolted down yet, but it will work. It's a really sloppy weld, but a weld nonetheless. The filler rod I got was way too small in diameter to be useful.

Haven't done much with the Manco cart. Got a cheap abrasive blaster so I can start taking the paint off of it.

Jim

 

[redsox985]

When cutting with a torch don't try to blast thru the plate in the center. Start at the edge and clean it away slowly. Like a plasma cutter.

 

[Blazkowiez]

It looks like you're going to end up bolting that down to the frame and putting pressure on the shaft... thats a bad thing.

 

[turbojimmy]

It looks like you're going to end up bolting that down to the frame and putting pressure on the shaft... thats a bad thing.

I'm going to put washers between the plate and the frame. I erred on the side of making it too short rather than too long. Just right would have been nice, but I didn't trust my skills enough to manufacture something that precise.

 

[That One Guy]

The weld on that bracket looks a bit flimsy... I would go over that again and try to stay in the crack. Sloppy welds are absolutely fine as long as they hold.