uk
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
Building a Go-kart
Yash Patel, Om Patel, Shivam Singh,
James Stack, Paras Mehrotra, Varun
Srirambhatla, Shyam Jayabal
Why this?
• This is a challenge for us as part of our skill set is doing
technical jobs however only on a more non-electronic side.
Thus with our basic electronic knowledge, this will be a
challenge for us to make a fully functioning go kart which is
wired as per safety standards and works effectively as well.
• The designing aspects will be challenge for us due to us having
to visualize the entire theme we will apply to the kart and
making it go from a functioning frame to an aesthetic model
• Finally through this project, we will most importantly develop
problem solving skills but also have fun whilst working with
friends and letting our imagination run freely through
designing the kart.
Our experience
Name Qualifications/ experience
Yash Patel A level DT student (with a Grade 9 in GCSE DT)
I have completed multiple engineering related work experiences
[email protected]
I have received the Arkwright scholarship for engineering
k I am passionate about design, and have a depth of knowledge of tooling and have practical workshop experiences through many projects
I passed the Solidworks CWSA CAD exam and am now an Associate (and am working towards achieving CWSP qualification)
Om Patel A level DT student (with a Grade 9 in GCSE DT)
[email protected] I have completed multiple engineering related work experiences
Winner of Big Bang National Competition
I am passionate about design, and have a depth of knowledge of tooling and have practical workshop experiences through many projects
I passed the professional standard of Solidworks CWSP CAD exam and am working towards achieving expert CSWE qualification
Job-Entry level cybersecurity qualification Yo
Shivam Singh A level design technology student yo
[email protected] Multiple engineering related work experiences
Taken part in robotics over the past 4 years
Passionate about design, depth of knowledge of tooling, practical workshop experience over the past 6 years
Have successfully completed a number of practical/ design projects
Professional standard cad modelling certified cswp
Shyam Jayabal A level physics student with predicted A*, Few engineering related work experience, Interested in Physics and modelling
[email protected] Have successfully completed a number of design technology projects
Have completed Willis Tower Watson and LIIBA Industry STEM insight (certificate available)
Paras Mehrotra A level physics, maths and further maths student with predicted A* for all 3
[email protected] Engineering work experiences with Bentley, Siemens and Capgemini (certificate available)
Attended the Engineering Development Trust routes into Stem and qualified as an EDT Bronze Industrial Cadets
Have successfully completed some design and technology projects, Passionate about design and modelling
Varun Srirambhatla A level DT student (with a Grade 9 in GCSE DT)
[email protected]. I am passionate about design, and have a depth of knowledge of tooling and have practical workshop experiences through many projects
uk VEX Robotics Team member for 4 years, winner of national design award and many regional awards, Passionate about design, depth of knowledge of tooling, practical workshop
experience over the past 6 years, Have successfully completed a number of practical/ design projects
Working towards CWSA CAD exam
Risk Assessment (note: when using the technology workshop in our school, we
require supervision from a tutor at all times, who will help deter and reduce any risks)
Hazard Who might Protective measures Likelihood Severity (1- Risk Further action
(1-5) 5) (L x
be affected S)
Laceration from Group • Taking care when using tools 4 3 12 • Wash with cold water, sterilise, apply pressure
power tools e.g. band members • Keeping fingers away from no-go zones • Inform supervisor/ DT teacher
saw, angle grinder • Wearing protective gloves and PPE where needed. • Rethink the process being carried out
• Learning how to use power tools • Wear PPE
Burns from saws, Group • Keep fingers away from cutting/soldering/welding 3 3 9 • Run under cold water for 5 minutes
soldering iron, members, area • Petroleum jelly to heal burn
welding, brazing teachers • Learn how to use machinery properly • Protect area from sun/stimulants
hearth • Allow parts to cool before use • Allow blistering to occur and do not pierce in
• When using brazing hearth, use heatproof gloves case of infection
Toxic fumes from the All users of the • Use sufficient extraction in all rooms when working 5 2 10 • If you feel lightheaded or cannot breathe,
processing of material technology and up to an hour after (inevitable) (all appropriate
safety measures
switch off all machinery and exit the room
e.g. bending plastic, workshop • Wear masks when necessary, for example when already in place • Go outside and breathe fresh air
welding spray painting and welding + supervision)
• Drink water; do not resume until comfortable
Irritants in eyes Group • Use safety goggles at all times, even when not 3 2 9 • Use eyewash kit to wash eyes with tap water
members using tools. • Allow natural blinking and crying
• Use sufficient extraction or blow to clear • If soreness, swelling or redness occurs, seek
workspace of sawdust/metal filings further medical advice
Testing of go-kart Group member, • Set out a clear and controlled track, to avoid 2 3 6 • Stop the go kart immediately in any case of
driver and people getting in the way emergency and get out if the situation
anyone present • Incorporate a seatbelt into the design permits
• Make sure that you are supervised to make sure • In the event of someone being hit, ensure
people know that we are not just playing they aren’t badly injured before continuing
• Wear a helmet in case you fall or the go-kart breaks • In the very unlikely event of a fire, extinguish
• Fire extinguisher…. (just in case) any flames as quickly as possible using a blue
fire extinguisher
• Make arrangements with the school technology
department to use their facilities and workshops
How will we
• Regular meetings where we discuss the project plan
do it? What for the following week
arrangements • Allocate roles which are suited to each other's
need to be strengths, but also allocate roles in which people can
learn new skills
made? When
• Schedule review sessions where we review our
and where Progress
will we build • Schedule testing sessions in which we analyse and
it? evaluate specific components or the go karts overall
performance, and determine the next steps in the
refinement of our design
• Will take approximately 6 months to complete
•We will split up this project into different aspects of the go
kart where a couple people will specialize.
•2 students will prepare the parts individually such as
marking out and cutting the parts to size
•2 students will learn how to weld through the help of our
technology teacher who will then put the main frame
together
Roles •2 students will focus on the final assembly of the project and
understand the way the kart goes together.
•Overall we will have everyone helping the 2 main experts
within each aspect of the project
•1 students focuses on the short film we are aiming to create
Drawings
Technical
Sketch
Costs in detail
• What we need:
• Mainframe: The mainframe is the metal construction of the go-kart, and other parts
work around this. We will need to cut, drill, and weld hollow metal tubes to give the
mainframe a shape for this build. All the equipment such as coping saws, hack saws,
metal band saws... can be found in the school workshop.
• Drive Axle: The drive axle is the joint between the split axles at the front and back
of the go-kart. This part somewhat controls the wheel’s movement.
• Steering System: The steering system will have the overall control of the go-kart.
Though the steering system for this build will be pretty straightforward, we’ll still
require a steering column, wheel, brakes and a gas pedal to put it together.
• We can outsource parts we cannot build such as the motors, brakes, wheels,
steering wheel etc.
Parts List
Nuts and Bolts Quantity Goes Where?
5/8-11 x6" bolt 1 driver side dead axle
5/8-11 x4" bolt 1 passenger side dead axle
5/8-11 nut 4 front spindles, dead axle
1/2-13 x 3 1/2" bolt 2 spindle brackets
1/2-13 nut 2 spindle brackets
3/8-16 x 2" bolt 1 pitman arm
3/8-16 x 1" bolt 2 L+R spindles
3/8-16 nut 3 pitman arm, L+R spindles
5/16-24 (fine thread)x 1 1/4" bolt 1 motor shaft
5/16-18 serrated flange nut 4 motor mount
5/16-18 x 2" bolt 2 brake and throttle pivot
5/16-18 nut 18 brake and throttle bolts (2), seat slider (8), drive wheel (8)
5/16-18 x 1 1/2" bolt 8 motor mount(4), drive wheel assembly (4)
01/4-20 nut 10 steering wheel (3), kill switch ground (1), brake pedal (3) throttle pedal (3)
1/4-20x1 1/2" bolt 4 Seat bottom
/4-20 x 1 1/4" bolt 1 throttle pedal (top hole)
1/4-20 x1" bolt 5 brake pedal (2), throttle pedal (1), seat back (2)
1/4-20 x 1/2" bolt 3 steering wheel (3), kill switch ground (1),
Ctd.
Misc Materials Quantity Goes Where?
5/8 machine bushing 4 front spindles, dead axle
5/8 x 1" spacer 2 passenger side dead axle
1/8" cotter pin 1 front spindles, dead axle
5/32" cotter pin 1 brake band welded stub
3/8 x 1 1/4" clevis pin (or universal) 1 brake band
2 1/2" OD Flat Washer 1 steering wheel
5/16" washer 4 under seat slider
5/16" fender washer 1 motor shaft
1/4 ID 3/8"OD x1/2" steel spacer 1 throttle cable eyelet
male bullet connector 1 kill switch
thread locker (blue) 1 all nuts
black paint 1 brake and throttle bolts (2), seat slider (8), drive wheel (8)
frame paint 4 motor mount(4), drive wheel assembly (4)
primer 2 steering wheel (3), kill switch ground (1), brake pedal (3) throttle pedal (3)
3/4" ID x 1" spacer 2 steering shaft
4 1/2" angle grinder wheels 7 4 cut off, 1 sanding, 1 grinding, 1 wire wheel
Bulk steel materials Quantity Go Kart Parts Quantity
3/4" bore 10T centrifugal clutch 420p 1
3/16" plate (12"x12" section) 1
4" brake drum 1
11ga 1"x1" sq tubing (10 ft section) 5 3/16" x 1/2" keystock 1
4" brake band 1
16 ga sheet metal (26"x20" section) 1
throttle cable (manco) 1
11ga 3/4" round tubing (18" section) 1 manco throttle return spring 1
manco brake return spring 1
1"x1"x1/8" angle iron (1" section) 1
heavy duty gas/brake pedals (L+R pair) 1
3/8" round bar (36" section) 1
kill switch (1/2") 1
1/4" round bar (72" section) 1 steering wheel 1
3/8 x 8" tie rod w/ tie rod ends 1
GO KART PARTS QUANTITY
3/8 x 18" tie rod w/tie rod ends 1
140/70-6 knobby tires 4 spindle (L+R pair) 4" center to center 1
3" spindle bracket w 1/2" kingpin holes 2
6" rims 3
seat slider (8" mounting pattern) 1
6" drive wheel with hub 1 motor mount plate 1
420p chain 1
5/8" ID 1 3/8" OD sealed bearings 1
420p master link chain connector 1
60T drive wheel sprocket 420P 8
bench seat 1
Costs of parts
list
• Our total cost is around £850
• However, the highlighted materials on the previous two slides are
materials we will be able to find at school.
• We can also request the school to order some materials on our behalf
for cheaper prices.
• We can also look to find used materials for cheaper prices.
Reducing Our Costs
• Many of the nuts, bolts and washers will be available in school for us
to use
• The school also has square tubing and round bar, and will be able to
get sheet metal for a cheaper price
• We will cut out 1"x1" steel tubing into the base frame, and weld it together. The bottom corners are
cut on 45 degree angles.
• Then cut out pieces for the bumper, the 'rounded edges' are cut 67.5 degrees measured from a
protractor. Then drill 5/16" centered holes through the tubing at 1 1/8" from the end of the tubing
for brake/gas pedals.
• Next, cut out a 25 3/16" section of 1"x 1" square tubing, and weld 5/8" bolts to each end. The 6"
bolt goes on the driver side of the kart, and the 4" bolt goes on the passenger side of the kart. Weld
the axle underneath the base frame 7" from the inside edge of the rear of the kart frame.
• Continue to weld the 16 ga sheet metal underneath the base frame, drilling two holes through
which a bolt will be inserted to a seat slider. Floor pan dimensions are 26"x 20". Weld the motor
mount to the frame as the last step to ensure the engine clears the seat frame.
Method • Seat sliders bolted onto the frame and then the seat on that.
• Then we will cut out an 18" section of 3/4"x11ga tubing and weld together the steering tabs. The
pitman arm, 1"x1"x1/8" angle iron, tab that will hold the shaft to the frame, and spacer. Center and
weld the spindle brackets to the front axle. No camber or caster is built into this kart, and it steers
well.
• Brake and Throttle pedal stop tabs are used to keep the brake and throttle pedals in their resting
position, and full forward positions. Weld the 3/8" round bar to the frame. This stud will serve as
the pivot for the brake band. Weld this tab to the kart with the brake rod already bent and inserted.
Fine adjustments may be made with the brake band installed by bending the rod itself. Bend the
1/4" round rod leaving extra on both ends. Cut as needed and weld the eyelets to the rod with the
brake pedal installed with return spring.
• Finally we will weld this tab to the kart, about 4" back from the center of the throttle pedal bolt
hole, on a 45 degree angle and use 3/8" rod, and bend it in a vise with hammer to make a foot rest
for the passenger. This keeps the feet from resting on the tie rods.
Testing
• In order to test the go kart we will be driving it with safety protection
on the driver such as a helmet, knee pads and elbow pads. We will
test its speeds by timing the go kart over a set distance at the back of
the school under adult supervision.
• Finally once we are done with the project we would display it either
at school, or show it at the annual QE design showcase.
