Go-kart project video

[Aaron]

I am finally producing proof of my go-kart project. :D

The following video was taken Chrismas day, 2003. The driver is my brother in law, and the passenger is my 8 year old son. The video was taken at my in-laws place.

I apologoze for the poor resolution. File size limits what I can save here. I have much better footage, but I am unable to display it here. :(

I made everything you see except the motor, the brake-caliper, the seats, and the wheels/tires. Fun project for a beginner.

[bomberz1qr20]

One word: sweet.

[Aaron]

The only thing I welded with my MM251 was the mount for my homemade steering gearbox. The resat was welded with my HH175. All the heavy stock was either welded at work (after hours, of course :D) or multi-pass welded. The items welded at work included the front and rear wheel hubs, which are 2" diameter barstock welded to 1/2" x 4" x 4" plate.

This should give you some idea of the type of projects you can complete using a HH175.

[morpheus]

that's cool aaron !

how fast will it go ? If it will go very fast I might consider adding some lateral bracing to the cage ... and maybe a bar to triangulate the "roof" section since it's pretty big and open.

[Aaron]

It goes about 15-20 mph, which is plenty fast for the kids. It goes about 15 thru the field, but 20 on pavement.

I considered th bracing, but the entire thing is pretty ridgid. It has already smacked a tree to prove the point. :D It is as wide as it is long, and the CG is relatively low, so i don't see it flipping at 15mph.

[Aaron]

And right now the driven sprocket I've used is the largest one I can buy thru my local bearing house. :D That should translate into some serious speed when the kids are older! :D

[cutter]

Very cool, Aaron. Your kids will remember this forever. When I was really just a toddler my dad
made us a couple of pump cars using axe handles for the sticks, You rested your feet on the front
axles to steer them & pumped the stick for power. I actually had to grow a year or two before I
could ride the smaller one & by that time my brother was saddling up his pony. The things my father
made for us are wonderful memories. I still have the wooden sword he made for my role as the
"Crimson Crusader" in a play in the second grade . And I have the table saw he used to make it
with :D as well as very clear images of him working on those things.
Priceless treasures.

[Jim314]

very nice Aaron. I bet the kids are really excited !! I know I would be, even now :)

[Jammer]

Nice job Aaron. Lucky boy there.

[rusted]

What was the material used? Pipe or tube? Diameter, thickness? (appears 1")
What did you bend it with?
How did you fabricate the hubs?
What did you make steering knuckles out of?
Can you get a shot of the steering box?

In short, I want details :p

If space for you is a problem, mail some stuff to me and I will host it on my websites for download linked here.

Nice job and looks safe and quite upgradable for the future.

[YJMike]

How did you get the brakes set up. I want to make a cart or minibike for my daughter, and this is really the only set back

[Aaron]

I will be posting some details soon, I promise. I am in the process of "reverse-engineering" my project, that is to say I am now documenting what I have already built freehand. :D

[Aaron]

Originally posted by rusted
What was the material used? Pipe or tube? Diameter, thickness? (appears 1")
What did you bend it with?
How did you fabricate the hubs?
What did you make steering knuckles out of?
Can you get a shot of the steering box?

In short, I want details :p

If space for you is a problem, mail some stuff to me and I will host it on my websites for download linked here.

Nice job and looks safe and quite upgradable for the future.

Material was a combination of 3/4", 1", and 1-1/4" pipe. I bent it using a H/V pipe bender purchased for $60 from the tool gypsies. Steering knuckles? I'll post photos soon. The steering box? Again, photos to soon arrive. :D It is basically two 1/2" aluminum plates, with a 1/2" shim between them. There is a bearing in the top and bottom plate, and the 1/2" shim corresponds to the thickness of the 16dp gear I used to move my rack back and forth, as well as the thickness of the rack itself. I then inserted a shaft through the bearing (the gear in between), and bolted a plate to the back to hold the rack against the gear. Behold, the rack-and-pinion steering box!

I appreciate the offer to host some of my stuff for posting. I may have to take you up on it. I can post photos okay, for now.

[Aaron]

Originally posted by YJMike
How did you get the brakes set up. I want to make a cart or minibike for my daughter, and this is really the only set back

I will try to post some photos by the weekend.

Basically, the caliper is from gocartparts.com. They sell everything you need. I chose to make my own mount for the caliper, as well as my own disc (rotor). I have the capacity to make parts, as I work for an OEM with an extensive manufacturing center.

[Aaron]

Rusted,

I almost forgot the hubs. :D

The hubs are basically 1/2" steel plate, 4.5" sq (I think). I tapped them for the studs, and bored a 2" diameter hole in the center. (all done in a mill for concentricity). I then made a 2" diameter hub, with a 1/4" chamfer on the outside of one end, which was for welding on the face of the hub. I then welded a bevel weld on the face, and a fillet on the reverse side of the hub.

After welding, back to the lathe where I turned the face of the plate square to the bore. Two of the hubs were bored out to 1.25" diameter for the rear axle (live axle) and keyed and setscrews. The other two were bored out for the front bearings.

I have since gone back and added zirk-fittings to the front hubs.

[Aaron]

All of these parts can be purchased at the local farm store or through Northern or Gokartparts. I just chose to make them myself as a learning process. My cart isn't pretty, but I take pride in the fact that I built it AND it's components. ;)

It is also pretty strong, as the kids have already proven repeatedly. Best part is, they are both learing to drive at an early age, on a vehicle that has little saleable value, so I need not worry about what they do to it. Besides, I can always make replacement parts, as I made the original parts anyway! :D

[Aaron]

This photo is of a "replacement" steering rack I made today on my lunch hour. After repeatedly being rammed into stumps and fallen trees, the original was pretty well bent beyond repair. :eek:

The rack is a 12" piece of 16dp rack with 14.5* pa.

Weld is SC, made with C25 and .035" wire, single pass.

[Aaron]

This is a closeup of one end.

The plate is 1/4" x 1" x 3-1/2" (approx.) CRS, with a 5/16-18 tapped hole for the tie rod end.

Note: I have also added a skid plate to the bottom of the cart to prevent having to make more of these. :D

[Franz]

Finest device ever made for destructive testing is the Mark I kid.
Kinda like when you really need to get the top off a childproof bottle, any kid can do it in half the time it takes an adult.

[Aaron]

LOL :D

About the time the words "stay away from that tree" crossed my lips, he smacked it at full throttle. :D Bent a 3/4" diameter tierod, and broke off the tierod end. Bent the rack to boot. But at least now he steers clear of the trees. :D

[Paychk]

Originally posted by Aaron
But at least now he steers clear of the trees. :D

And what is this called?

A life lesson, and one I'm sure he won't forget

Sure brings back memories from the one I had as a kid! :)

[teamnastybeast]

what kind of motor did u use

[Aaron]

The motor is a Tecumseh Sport, either a 6HP or a 6.5HP (I'm not sure which). I bought the unit at TSC last spring, as it came off the shelf ready for a go-kart. Price was about $250ish.

[rusted]

Well, it's even more impressive than I first thought. You fabricated all that stuff? WOW! Nice work!

[Aaron]

You haven't seen the closeups of my work yet.... :eek: :D

I have learned a lot since I started this project. It is evident when you look at the frame, for example. Six inches from a crappy weld is an good one, as I added stuff later. :D

As I said before, I wanted this to be a learning project, and I learned a lot. ;)

[morpheus]

I know exactly how you feel Aaron, on my 4x4 truck I see the things I welded on about 2 years ago and see the welds I've added recently and pleased at what I've done lately but kindof wish I could redo alot of what I've already done.

[Bolt]

Nothing a torch and grinder won't allow you to do!

LOL

[Aaron]

No torch yet. Besides, it adds character. (that's what I tell myself anyway) :D

[cutter]

Originally posted by rusted
Well, it's even more impressive than I first thought. You fabricated all that stuff? WOW! Nice work!

Aaron don't build no Orange County Choppers! :D

[Aaron]

Originally posted by cutter
Aaron don't build no Orange County Choppers! :D

I think that's my new sig-line! :D

Thanks!

[Franz]

Your old English teacher will be proud 2.0, but your wife won't be letting you tutor the kids any more.
Hmmm could there be method to 2.0s maddness?

[Aaron]

You read me like a book, Franzie! :D In your case, it must be a comic book! :eek: