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Functional Artist 10-09-2017 07:59 AM

2017 - !Arriba!
5 Attachment(s)
Picked up some 1/2" schedule 40 water pipe from Home Depot

itsid 10-09-2017 08:11 AM

and we'll see what you're going to do with it hopefully ;)


MTNSleder 10-09-2017 09:18 AM


Functional Artist 10-09-2017 02:55 PM

1 Attachment(s)
So's the plan :thumbsup:

Cut it up into several pieces

...(2) side rails

...(1) rollbar/seatback

...(1) steering support


...dig out the pipe bender

Functional Artist 10-09-2017 09:42 PM

3 Attachment(s)
Side rails (2 @ 56" ea.)

Left Rail

measure 12" - mark
measure 10" - mark
measure 20" - mark

put in bender
1. @ 12" do - 35 pumps

2. @ 22"do - 20 pumps
(inverted 180* from 1st bend)

3. @ 42" do - 75 pumps
(leaning inwards, toward 1st bend ~20*)

Right Rail

Do everything the exact same but, exactly opposite :thumbsup:

Functional Artist 10-10-2017 06:44 AM

4 Attachment(s)
Bends came out pretty good :thumbsup:

Welded the rollbar/seat back down to the (2) side rails

& welded the curled up parts to the back side of the rollbar/seat back

Functional Artist 10-10-2017 02:50 PM

4 Attachment(s)
Used a ratchet strap to precisely draw the sides together

Tack welded the ends of the sides to the front axle bar

That'll hold it together for now

Next, we'll square up the rear end :thumbsup:

landuse 10-11-2017 02:34 AM

Looking good so far!! Nice work

Functional Artist 10-12-2017 09:46 PM

4 Attachment(s)
Welded a ~16" piece of 1 1/4" angle steel across & between the side rails right where the rollbar/seatback come together

This is where the rear axle will mount & will also be the front support for the battery box :thumbsup:

The rear axle-

The original plan was to use (2) axles & (4) pillow block bearings


Unnecessary & too heavy

* Exploring options :cool:

ezcome-ezgo 10-13-2017 06:20 AM

Huh. I figured the rear axle would be hanging off the back loops.

Functional Artist 10-13-2017 08:45 AM


Originally Posted by ezcome-ezgo (Post 483583)
Huh. I figured the rear axle would be hanging off the back loops.

That's where the power pack & propulsion unit(s) go :thumbsup:


...for little & big @ the same time

small foot print with lots of room

& lots of power

But, also

...lightweight & heavy duty @ the same time

I am using a minimalistic approach

& trying to make it strong by design

Goals- :2guns:

easy to enter & exit

comfortable to drive

powerful - torquey & speedy (over 20 mph)

strong but, don't over build it (keep her ~100 lbs.)

Functional Artist 10-13-2017 11:31 AM

5 Attachment(s)
Picked up some stuff :thumbsup:

dual flanged hubs w/ 5/8" sealed bearings

6" drive wheels

72T #35 sprocket(s)

So, goin' with

15 x 6.00 - 6 rear tires & a 7.2:1 gear ratio :2guns:

ezcome-ezgo 10-13-2017 12:50 PM

I'm liking that Martin sprocket, they've got a plant just a few blocks from my house.

Functional Artist 10-13-2017 08:29 PM


Originally Posted by ezcome-ezgo (Post 483620)
I'm liking that Martin sprocket, they've got a plant just a few blocks from my house.

Yup! looks like good, quality stuff & made in U.S.A. :thumbsup:

Functional Artist 10-14-2017 10:49 PM

9 Attachment(s)
Next on the agenda

Motor mount plate 3/16" x 5 1/2" x 18"

used handy dandy cut off tool to whack off the excess material :thumbsup:

WOW! 5 lbs. just for the motor mount plate :ack2:

trim the corners & clean 'er up a bit

layout a grid pattern to help keep everything square

mark & drill (2) holes for each slot

(16) holes for (8) slots

used a Dremel to connect the holes

& a 5 1/16" drill bit to smooth 'em out :2guns:

Functional Artist 10-14-2017 11:21 PM

9 Attachment(s)
Made up a solid axle to mount the dual flanged hubs to

1 - 30" piece of 5/8" rod
2 - ~2" pieces of 3/16" angle steel (mounting brackets)
2 - ~1" pieces of 7/8" pipe (mount to hub spacer)

started by threading ~1" of each end of the rod

cleaned up a bit on wire wheel

drilled 5/8" holes in each mounting bracket to run the axle thru & 1/2" holes for mounting it to the kart

bolted the mounting brackets to the frame

run the axle thru (roughly centered)

slide a spacer on each end

slide a hub on each side

snug up with a fine threaded nut on each end

Now that everything is where it's supposed to be we can weld 'er up

just spot welds to tack everything in place

disassembled & welded 'er up good :2guns:

(don't want to get our new hubs all discolored from welding)

Functional Artist 10-14-2017 11:35 PM

5 Attachment(s)

that we know where the rear wheels go

we can get the motor mount mounted

drilled (2) 1/8" holes to tack the plate in place

to be sure nothing moves while welding

after welding

I removed the screws

& welded them holes up too :2guns:

Functional Artist 10-15-2017 07:26 AM

5 Attachment(s)
Next up is the steering support

think were gonna go a little different direction

...than our original drawing/concept :cornut:

using the same piece we bent

...just not

a big looping nose piece

...more of just a simple support

~12" seems to be about the right height

made a couple of marks

then lined up the angle, & marked

gonna split it in half

round em' up a bit

& weld a piece of pipe between

* got some pipe that will hold these grease able bushings
they are (originally) for riding lawn mower front wheels
should work good & never squeak :thumbsup:

landuse 10-16-2017 01:04 AM

Wow!! Awesome work so far. You should be finished in a week :D

Functional Artist 10-16-2017 06:44 AM


Originally Posted by landuse (Post 483881)
Wow!! Awesome work so far. You should be finished in a week :D


It's mid-October already

Winter here in Toledo (my busy season)

could show up @ anytime

So, gotta move it along :thumbsup:

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