First off,

Why make custom steering parts for Go karts and ATV’s? When building go karts, side by sides, or complex assemblies from scratch or from an assortment of salvaged parts, store bought parts will most likely not meet the demands and angle requirements that you need. That is why we set out to find the most effective way to make our own parts to adapt to the situation.

For example: In our case, the original steering plans would not work with the additional shock travel provided by our custom front end design.

Supplies

Step 1: Collect Parts Needed

Note: almost all parts can be found second hand for better prices but be wary of quality and make sure you vett parts before trusting your life with them.

(Main steering assembly )

Option 1: Homebuilt tabs and tie rods (Less precise and requires more fabrication but less expensive)

Option 2: Basic rack and pinion assembly: Basic Rack and pinion on Amazon (More precise and requires less fabrication however it does cost more) These can be found at most equipment stores or on second hand websites like Offer up and Craigslist. This is where we found ours and what we recommend for finding the best price.

Threaded Tie rod ends : Tie rod ends at Tractor supply/ Tie rod ends with Shafts

Angle Iron for custom attachment bars: You can size up or down and make custom dimensions with Industrial metal supply depending on the project weight and dimensions.We ended up settling on ¼ x ¼ x ⅛ Here is what we used. Industrial metal supply Angle iron

Assorted metal plate for making a mounting base:

For this, any cold rolled steel plate will do however by wary of going to thin as it needs to hold up to the stress of all the steering components. Ours was 1/4 inch. Industrial metal supply plate and sheet metal.

Step 1: Collet Tools Needed

Tools needed:
Mig Welder and Accessories
Hammer
6 inch Starrett Steel Rule(Any measuring device will work)
Angle Grinder
Grinding Blade
Cutting Blade
Drill
Drill Bits
Basic Fabrication Skills ( It is expected that if you are building vehicles that require such modifications some prior skill is not a problem)

Step 2: Mounting Your Steering Rack

Mounting your steering rack
Cut a small 2.5” x 1” steel plate
Measure 2 holes that match up with your steering rack mounting bolts
Drill holes out to the size of your steering rack mounting bolts(ours were ⅜)
Acquire longer bolts from the hardware store(Ace) and washer to fit
Tighten down the plate on the steering rack while spacing out the bolt with washers(this will prevent you from locking the rack into place)
Center and square your mount plate
Do this by measuring and ensuring you are equidistant from the edges of your front end, as well as equidistant from each tire while square.
The tires can be squared up by ensuring that both the front and rear of the tire are equidistant from each other
Secure the tires either using blocks or clamps, once centered clamp your plate in place
Then tack weld your plate on and recheck for squareness
Then fully weld your plate on to secure it down

Additional: If using home-brew steering tabs the steel plate will be drilled to except the end of the steering shaft for stabilization. The tabs can then mount to the end.

Step 3: Shortening the Tie Rod Shafts

Cut bars in half, cut 1 inch from the threads on either side
Clean the welding area
Secure both sides together and tack weld
Check to ensure they are straight and finish weld all around
Double-check straightness and if they are too crooked then cut and re-weld

Step 4: Assembly Pt. 1

Screw shortened tie rods into the steering rack
Screw tie rod ends onto the other side
Leave room for adjustment in both directions

Step 5: Assemble and Measure for Custom Attachment Bars

Measure the distance between the base of your tie rod end and spindle bracket
Get your angle iron and cut down to 150% longer than your measured distance
Now go 1.5” up your angle iron and make a pie cut on one side of your angle iron
Then bend the metal so the empty pie cut becomes filled and flush
Then make a full cut along the same side of the angle iron and a notched cut on the other side of the angle iron to bend out/opposite direction
Make that cut about 2” from the other end of the angle iron
Now bend both bends to the desired angles in order to line up flat and flush with both your tie rod end and your spindle bracket
Once you have the desired angle, pull the piece and make an exactly identical custom attachment bar for the other side
Now ensure both are the same size/shape
Then weld bends together to make secure and stiff
Then drill a hole(ours was ⅜”) for the tie rod end to bolt through
Once this hole is drilled, cut down the metal to the edge of the hole
Then size up and cut down the bottom side to the proper length
Then weld the bottom part to the spindle bracket