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How to Make a Go-Kart by thegokartguy on April 7, 2014

Table of Contents

How to Make a Go-Kart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Intro: How to Make Make a Go-Kart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Step 1: The Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Step 2: The Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Step 3: Welding Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Step 4: Attaching the Axel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Step 5: The Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Step 6: 6: Tie Rods Rods and Pitman Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 7: Seat Bracket and Floor Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Step 8: Motor Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Step 9: Mount Engine, Chain, and Torque Converter Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Step 10: Hook up up and Assemble Pedels Pedels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Step 11: Test Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Step 12: Tear Apart and and Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Step 13: Put Back Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Step 14: HAVE FUN!! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Intro: How to Make a Go-Kart Design The first thing you need to do, is make a design. You have to design everything for it to work out in the end. First is to design the frame. How big is it going to be, how wide? Draw it on a sheet of copy paper first and think of how long you want it. Figure out all of the dimensions and angles in it. Next, transfer the small drawing on to a big sheet of paper so that it will be the exact size that the frame will turn out to be.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 1: The Jig The next step is to build a jig. A jig will help a lot with building the frame. After drawing out the design to the exact dimensions, lay it out on a sheet of plywood. Then screw 1x2 down all around the frame part . After this, take the paper off and you have a jig.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 2: The Frame After the Jig is built, the next step isa to make the frame. I used 1 1/4 inch steep square tubing. Cut the steep at the right angel and put it in the Jig. I also had to bend the two side peices because it would be weaker if I had cut and welded them. To cut the steel, I used a horizontal bandsaw.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 3: Welding Frame After all of the pieces fit together in the Jig, the next step is to weld it all together. Weld all of the top joints and then flip the frame over and weld all of the bottom ones. After welding, grind all of the welds down to a smooth finish.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 4: Attaching the Axel After all of the welding and grinding, the next step is to attach the axel. Go ahead and put all of the components on the axel in order, but they don't have t o be lined up yet. Drill holes through the frame and attach the pillow blocks to it with bolts. In the pictures the frame is upside-down. Attach the axel so that the pillow blocks bolt holes are upwards towards the frame and the axel is below that. After attaching the axel, put the back tir es on.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 5: The Front Next step is to attach the front C brackets which holds the spindles. Tilt them back a little if the front tires are smaller than the rear ones. Once you have them mounted, then put in the spindle with the kingpin.Then put on the spacers, washers and front tires. (I replaced all of the washers with PVC pipe and left one washer on either side of the wheel.)

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 6: Tie Rods and Pitman Arm For this step, have a piece of steel attach to the steering shaft and attach the tie rods to the top of it. Then, attach the other end of the tie rods to the spindle. To hold the end of the steering shaft, I put a pillow block on there and also fabricated a holder for it.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 7: Seat Bracket and Floor Pan Next is the Seat bracket. To make it, map out where you want it and cut it out of some heavy duty steel. I used some diamond plate. After you cut it out, measure and drill holes for the seat to attach to it. Then weld it to the top of the frame. For the Floor pan, it is pretty much the same thing. Map out where you want it and cut it out of steel. I used the diamond plate again. After cutting it, just weld it to the frame.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 8: Motor Mount Next is to make the motor mount. I make it out of steel that I cut and welded together. If your kart is at an angel then make the front of the mount higher than the back and use a level to try to make it as level as possible.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 9: Mount Engine, Chain, and Torque Converter Next is to mount the Motor, Chain, and Torque Converter. First put the torque converter on the engine and make the bolts nice and tight and use lock washers. Make sure that the belt is on the right way and all the keys are in the key ways. Next, mount the motor on the motor mount, but don't tighten it down yet, put the chain on first. Put the chain in with the master li nk and have the clip facing away from the engine and the round end of it going the way that the chain is going to be turning the most. Then, pull the engine back to get the chain tight and tighten down the engine with bolts.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 10: Hook up and Assemble Pedels For this part, either f abricate or buy some pedals and find out a way for them to attach to your frame. Then, attach a cable from the engine to the pedal and set up the throttle linkage. For the brake, make a rod that goes from the lever on the caliper to the top of the pedal.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 11: Test Drive After everything is set up and working, put the right oil and gas into the motor and take it for a test drive. For a Predator 212cc 6.5hp it takes 10w-30 oil and unleaded gasoline. Let the motor warm up a while and break in.

Step 12: Tear Apart and Paint For this part, strip down the kart to the bear frame and prime it and paint it. First, since there was a lot of rust on mine, I sand blasted it and got all of the rust off, then primed it, then painted the spots that I wanted to be orange, orange. Then I put pin striping tape over it and painted black over that then pulled the take off carefully.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 13: Put Back Together Next step is to assemble the go-cart and get everything hooked up again and working.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Step 14: HAVE FUN!! Go rompin and get muddy, do some doughnuts and have some fun!!

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

Related Instructables

no weld go kart part 1 (Photos) by BIGHAIRYDUDE

How to build a Roll Bar by DragsterIOW

how to drift in a go kart by irondirtboy

Go kart 2012 (Photos) by QSDR

Mini Tractor From Go kart parts (Photos) by flyingchainsaw

Electric Go Kart From Old Trash (On a Budget) by saxmaster765

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Comments 36 comments Add Comment

primosanch says:

 Apr 24, 2014. 9:52 AM REPLY

Nice project. Thanks for sharing.

00017095 says:

 Apr 24, 2014. 9:42 AM REPLY

Thats my boy

legamin says:

 Apr 24, 2014. 9:17 AM REPLY I love every part of your design except the steering column mount that i s so immediately straddled between the legs. There r eally isn't a lot of travel between hitting an immovable object and permanent vocal irr egularity. But wow! Thanks for a clear presentation to get us on our way!

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

wiredcav says:

 Apr 24, 2014. 9:11 AM REPLY

Beautifully done!

MacGyver4th says:

 Apr 24, 2014. 8:56 AM REPLY

Excellent job. You should be proud. Any plans on pursuing a degree in engineering?

Litovcas says:

 Apr 24, 2014. 8:30 AM REPLY

Vmax? :D

dlindstrom says:

 Apr 24, 2014. 7:57 AM REPLY

Excellent job kid!

pooter1433 says:

 Apr 24, 2014. 7:53 AM REPLY

Great job dude! Looks cool and the bike steering mount is a great idea!

excavatoree says:

 Apr 24, 2014. 6:17 AM REPLY I see one improvement: The kingpins are angled t oward the rear, but they need t o be angled in the other plane as well. The best way to describe i t is that a line through the center of the kingpin should intersect the contact patch of t he tire. There are some youtube videos on steering geometry that show this. It's a great design with a lot of attention to detail.

thegokartguy says:

 Apr 24, 2014. 6:40 AM REPLY

When I was building this, I checked the camber, caster, ackerman and tow

excavatoree says:

 Apr 24, 2014. 7:15 AM REPLY This is different from those parameters. They relate to the wheel in it's location, the kingpin angle affects t he geonetry of the steering in a different way. Your wheels aren't pivoting on the contact patch, but are making an arc - thus making the vehicle more difficult to steer and hold. (any force acting on them has a larger moment arm with which to push the steering wheel and other front wheel.) I was trying to find the relevant youtube video, because the person who made it explains it far better than I can. Here's one, but it's not the one I had in mind. You want to elimi nate the "scrub radius." https://www.youtube.com/watch?v=IUcZ63unEyU

calderS says:

 Apr 23, 2014. 4:32 PM REPLY

That's not a go kart this is

thegokartguy says:

 Apr 23, 2014. 6:30 PM REPLY

Why does mine not qualify?

Reichenstein7 says:

 Apr 24, 2014. 7:15 AM REPLY Yours absolutely qualifies. Some people just don't have anything nice to say. Btw, I have done a simil ar build with my father maybe 15 years ago, I never thought of cutting up a bike f or the steering components, I like i t.

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

PatJones says:

 Apr 24, 2014. 4:29 AM REPLY

That's not a go-kart. It's a sand crawler.

MrNathann says:

 Apr 24, 2014. 7:09 AM REPLY

Great job That thing looks like a riot ;-)

10033596 says:

 Apr 24, 2014. 6:56 AM REPLY

COOL DUDE

10013924 says:

 Apr 24, 2014. 6:53 AM REPLY

That's my boy! I knew you could do it.

ljm911 says:

 Apr 24, 2014. 6:28 AM REPLY

I'm 12 and I'm trying to rebuild an old ford tractor but I think you've got me beat. nice job!!!

thegokartguy says:

 Apr 24, 2014. 6:37 AM REPLY

Thanks, and good luck with the tractor

croxly says:

 Apr 23, 2014. 8:45 PM REPLY

How much does it cost? And what engine power

thegokartguy says:

 Apr 24, 2014. 5:58 AM REPLY It was about $700-$1000 and I paid for mostly all of it myself. The engine is a Predator ( Chinese Honda Clone)212cc 6.5hp from Harbor Freight

jmwells says:

 Apr 22, 2014. 6:15 PM REPLY I can see you definitely built this for durability, not track speed. Good job! So, when are you starting on your first off-road 4 wheel monster? Haha

thegokartguy says:

 Apr 23, 2014. 6:12 AM REPLY

Maybe after I fix up some 1869 Yamaha Enduros, and a 1987 Jeep Wrangler. And by the way, I am only 13 years old.

NoseyNick says:

 Apr 24, 2014. 5:11 AM REPLY

Fantastic work. I'm in my 40s and I'm envious of your welding skills! :-)

thegokartguy says:

 Apr 24, 2014. 5:54 AM REPLY

Well, I had a little help from my dad with some of that...

jmwells says:

 Apr 23, 2014. 7:06 AM REPLY

I was just kidding. I figured you were younger. Still, a goal to look forward to.

ncanm1234 says:

 Apr 22, 2014. 9:25 PM REPLY

Video? On you tube please?

00021265 says: He tried including a video with his right before the end but the file ended up messing up

http://www.instructables.com/id/How-to-Make-a-Go-Kart/ 

 Apr 24, 2014. 5:33 AM REPLY