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.
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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.
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.
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.
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.
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.)
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.
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.
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.
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.
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.
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.
Step 13: Put Back Together
Next step is to assemble the go-cart and get everything hooked up again and working.
Step 14: HAVE FUN!!
Go rompin and get muddy, do some doughnuts and have some fun!!