How to Build the Ultimate Offroad Go-Cart

Always wear proper safety equipment.

Offroad go-carts are small high- powered vehicles designed to tear through mud, hills, and brush. The ultimate offroad go-cart is one that can not only go through any terrain unscathed but do it in the fastest time possible. A detailed build guide is necessary to complete the task, as there are many highly detailed steps to take. The project can take several weeks or months to complete and the scale and scope is really limited by budget. As of this publication, it's quite probable you can expect to pay well into the thousands of dollars. A new chassis and engine alone costs about $3,000. The cost varies significantly, based on the components used. For example, a used engine will be much less expensive than a new one.

Things You'll Need

• Detailed build manual
• Fully stocked garage with tools
• Engine
• Chassis
• Transmission
• Suspension
• Wheels and tires
• Assorted parts

Instructions

1. Select a chassis. The chassis is the metal frame of the vehicle. Most will accommodate one or two riders. High performance go-carts are almost always equipped with a single seat. However, for offroad racing, where a navigator is required, two-seaters are used. Select a chassis that fits your needs.

2. Select a 1,000 cc or 1,200 cc dirt bike engine. This engine is tuned for high performance and durable enough for rugged conditions. It is also the largest engine available for go-carts. Larger engines will be heavier and not necessary for carting.

3. Install a high performance six-speed sequential transmission with paddle shifters. This type of transmission will provide the best performance and be the most versatile for the driver. Paddle shifting will make shifting easier and result in higher performance.

4. Select wheels and tires. Off-road go-carts need large heavily treaded tires. Large tires provide more grip and allow the vehicle to go over larger objects with ease. They also help soften the ride. The tires must have a large tread; the tread helps with grip and getting the cart through mud, dirt, sand and brush.

5. Install a suspension. The suspension is vital to performance and safety. Offroad racing requires a very strong and flexible suspension. The suspension should be adjustable and designed for offroading racing. Adjust the suspension to suit the terrain and style of the driver. A hilly track with jumps may require a certain setup, while a flat sand track will require another one.

6. Select the best performance parts for the go-cart. There are literally hundreds of parts that are required to build the ultimate offroad go-cart. Consult a builder manual or builder, along with a high performance racing store to determine the best parts for the vehicle. Since the best parts are constantly changing due to new models and upgrades, the builder must actively look for what is currently the best.

7. Build the go-cart. Hire a builder or work with a detailed build manual to manufacture the vehicle. Building a high performance cart to the best it can be requires a detailed knowledge of the craft.

References

• "Build Your Own Off-Road Buggy for as Little as 100 Pounds"; Ron Champion; 2002
• “Go-Kart Racing Chassis Setup: A Complete Guide to Setting Up a Winning Kart Chassis"; Brian Martin; 1996
• “Building a Dune Buggy: The Essential Manual”; Paul Shakespeare; 2006
• “How to Build Motorcycle-engined Racing Cars”; Tony Pashley; 2008