http://www.instructables.

com/id/How-to-Make-a-Go-Kart/
Food Living Outside Play Technology Workshop
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 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: Tie 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Step 10: Hook up and Assemble Pedels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Step 11: Test Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Step 12: Tear Apart 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 to 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 tires 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 link 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.
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http://www.instructables.com/id/How-to-Make-a-Go-Kart/
Step 10:Hook up and Assemble Pedels
For this part, either fabricate 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/
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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 is so immediately straddled between the legs. There really isn't a lot of travel between
hitting an immovable object and permanent vocal irregularity.
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 toward the rear, but they need to be angled in the other plane as well. The best way to describe it is that a
line through the center of the kingpin should intersect the contact patch of the 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 the 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 eliminate 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 similar build with my father maybe 15 years ago, I
never thought of cutting up a bike for the steering components, I like it.
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: Apr 24, 2014. 5:33 AM REPLY
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/
nahmed21 says: Apr 24, 2014. 5:21 AM REPLY
good job. it's would be good if available tutorial type video for this. I'm working for a project like this and will finished soon and publish. .. sharshongbd. got some
idea from here, thnk you.
PatJones says: Apr 24, 2014. 4:30 AM REPLY
Great work. 13? Ever consider a career as a mechanical engineer?
pablo de paris says: Apr 23, 2014. 9:54 PM REPLY
13 and building this!!! By 18 you are building spaceships. Congrats
ncanm1234 says: Apr 22, 2014. 9:26 PM REPLY
How did you manage mud on the top of your boots if they were facing you? Just curious
thegokartguy says: Apr 23, 2014. 6:37 PM REPLY
The day that this was taken, I was dirt biking and riding this.
Cavechild says: Apr 23, 2014. 9:03 AM REPLY
Awesome build and really nice write up with loads of clear photos, keep up the good work.
samuraijack says: Apr 23, 2014. 3:32 AM REPLY
i wish someday i would be able to replicate your instructable.
make my own cart based on your tutorial..
You sir are awesome.