University Senior Project Go-Kart

[corvet95]

Hello friends,
I am new to the site and new to karting. My friends and I are creating a go-kart from scratch as our senior project for University. We have already checked out this site when doing research and we think this is a great community to be a part of. The university we go to will (hopefully) be reimbursing us of the money we spend as long as it is reasonable. I believe the average amount spend is somewhere between 500-1000 dollars. We have a lot of questions and will be frequently visiting this site for advice.

Basic idea:
Create a go-kart from scratch by making use of the University machine shop and resources.

Outline:
1. Lay out basic components and prices of them in spreadsheet
2. Formulate design for frame and chassis
3. Build frame and chassis using University machine shop
4. ???
.
.
.

So far we have only just began and the only part we actually have is a predator 212cc engine (it was on sale and i didn't want to miss the good price) from harbor freight. We know that the engine needs a break-in period and plan to run it while we work on the frame and chassis design/build. Soon (hopefully in the next few days) we will be finalizing a design for the frame and chassis and will start manufacturing asap. The University does not have a welding lab and i do not know how to weld. However i can borrow a MIG welder from someone and use it. Is it difficult to self teach welding to a point to manufacture this frame/chassis?

This is the only question i have as of now but i am sure that many are soon to come. Should i post them as responses to this post or make a new thread? Thanks for taking the time to read this!

 

[Bwdeaton]

For building a frame ground up, I would recommend some training and practice with the welder.

The frame design can be hand drawn or 3d modeled if you know how to do that, and members here would be willing to look at the design and give honest feedback.

You will easily spend 500 on axle, brakes, sprockets, Torque converter or CC, and everything required to put your driveline together, and then you will still need more parts including wheels, tires, steering, hubs, and a seat.

Some steps you should start with:

Watch videos on welding and then get some practice as often as you can.

Start building a list of what you think you need, and ask as many questions as you want about part recommendations and suppliers.

Share the list and members here will be able to remind you of anything you may have missed.

Design a frame, preferably look at karts online to come up with an idea of what you want to do, then visualize the idea onto paper or into a computer drawing.

Good luck with your designs!

 

[corvet95]

Hey Bwdeaton, Thanks for your reply!

We could probably do a formal design either by hand or on some CAD software.

we are under the impression that there are no issues getting reimbursed from the University as long as it is reasonable so we don't think total cost will be much of an issue, however we would like to save money where i can because this is temporarily coming out of our pockets.

I have watched a bunch of videos on welding and i am usually a fast learner. I know someone who can weld should i have an issue.

We have a list! It is a google doc found here
Feel free to tell us anything we should include (i know we are missing a lot of components but we are slowly filling it in as we think of them).


We have an idea of what the frame/chassis should look like but it is very rough and we are going to finalize it during our next meeting.

 

[OzFab]

This is the only question i have as of now but i am sure that many are soon to come. Should i post them as responses to this post or make a new thread?

Post them here; we prefer longer threads relating to the same project over many short threads, makes it easier to keep up...

Some may have issues reading the google doc, it's best to post the list of items here...

However, I didn't have an issue & that is a very short list, that's probably about half of the necessary parts; here are some more:

-Front spindles: as a machine shop project, these can be made but, will require welding

-Tie rods, steering wheel boss & steering shaft: the tie rods & steering wheel boss (the piece that connects the steering wheel to the steering shaft) can be turned easily enough but, the ends will need to be purchased (unless you're capable of making a small ball joint); remember, the tie rods will need a RH thread on one end & a LH thread on the other, this makes adjusting easy without having to disassemble the entire front end; as for the steering shaft see comments regarding spindles...

-Wheel hubs: after you purchase the wheels, turn them to fit both the wheels & axles; if you want to "cheat" & buy wheels with integrated hubs, you may lose marks...

There's lots more; when you post the parts list here can you please post a list of parts you intend to buy (or have already bought) & a list of parts you intend to make...

Does the uni have a tube bender (not to be confused with a pipe bender)?

IMO, round tube is the better option because square tube may require more welds & welds = weak points; your professors will know this; having said that, this depends on the answer to my previous question...

I won't overwhelm you with too big of a wall of info right now but, suffice to say, there's much more to come...

 

[supermanotorious]

Perusing our site, you may or may not have read posts regarding my welding career, well to bring you up to speed, I'm in community college welding class 201 focusing mainly on TIG, the class takes place at a high school in Phoenix and this is the second time I've done course work here, I frequently look at the "trash" bin for the high school's shop, I see so much "scrap" in there that could be used to build pedals, mounts, you name it, I bring this up to say that your school likely has the same, think of Jesse James of Westcoast Choppers, now you may not agree with his social ethics but there is no denying his work ethic or fabrication skills, he'd have no problem recycling or upcycling steel scrap to make parts for his build

 

[Bosch]

You selected a good motor. I have two Predators and they run well.

 

[Hellion]

Don't forget your $99.99 coupon. Don't ever pay their list price but always have a coupon in hand (or on your smart phone).

Representative example:

 

[Flyinhillbilly]

When I'm building something structural I like to take some of the metal I'll be using and weld it and do destructive bend tests to make sure I get the amperage and speed right. The metal around the weld should fail before the weld does. Plus it's good practice.

 

[corvet95]

Thanks for the reply,
The University does not have a tube or pipe bender. is it worth it to invest in one in order to have a better final product?

 

[Flyinhillbilly]

Depends on what you're trying to do. I've used conduit benders with good results, I also own a mandrel bender, but I have about $1100 tied up in it. For the destructive bend tests I just weld a 90 degree joint and smash it in the vise until it gives.

 

[corvet95]

Does the uni have a tube bender (not to be confused with a pipe bender)?

IMO, round tube is the better option because square tube may require more welds & welds = weak points; your professors will know this; having said that, this depends on the answer to my previous question...

Thanks for your reply

We do not have access to a pipe or tube bender. Should we look into one for creating a stronger chassis as well as doing strength testing? I believe the University has some strength testing devices (tinius olsen).

 

[OzFab]

If you add your location to your profile page, you may find there's someone here close enough to help...

The University does not have a tube or pipe bender. is it worth it to invest in one in order to have a better final product?

in short, no; proper tube benders (as opposed to a pipe bender) start at around $300; it might pay to find a local business who is willing to help...

 

[nupmeyer15]

Look for some parts on Amazon. I know they have somewhat cheap spindles and pedals and other parts.


Sent from my iPhone using Tapatalk

 

[OzFab]

Did you notice this build is a university machine shop project? The more parts they make themselves, the higher marks they'll achieve...

Anyone can buy a bunch of parts & bolt them together; how many can make parts & have them work successfully?