How to Build a Motorcycle Go-Kart

A go-kart, also known as an off-road buggy or shifter kart, is a simple designed vehicle with a small body, four wheels, seats and brakes. Additionally, some go-karts have engines, such as a motorcycle go-kart, while others are designed with pedals to move. Building a motorcycle go-kart would require using major motorbike parts. In addition, installing some parts requires professional expertise since safety is a priority. For instance, engine installation necessitates hiring a mechanic.

Things You'll Need

• Chalk
• Tape measure
• Sheet metal
• Concrete blocks
• Notebook
• Steering system
• 25mm mild steel tubing
• Hacksaw
• Heavy-duty chains and sprockets
• MIG or MMA/stick welder.
• 4 tires
• Two steel axles
• 2-stroke motorcycle engine (8 horsepower)
• Steering wheel
• Front stub axle
• Centrifugal clutch
• Control assembly
• Torque converter
• King pins
• Steering column
• Track rods
• Pipe bender
• Bolts
• Locks
• Nuts and washers
• Support bushing
• 5/8-inch bearings
• Brakes
• Brake rotor
• Caliper bracket
• Marker
• Headlights
• 43.3-inch solid metal bar of 1.18 inches diameter
• Bucket seats
• Spray paint

Instructions

1. Draw out the chassis on the ground, or floor using chalk, sit in the chassis drawing to confirm there is enough room for the pedals, seat and steering wheel. Measure out the drawing using your tape measure and record your findings to your notebook. Essentially, for an average-sized driver, the go-kart should be 62 inches long and 47 inches wide.

2. Cut the length of your 25-mm mild steel tubing with a wall of 3 mm with your hacksaw based on the measurements you find. For an average-sized driver, the chassis should be made from 0.98 inches outside diameter tubing and a wall thickness of 0.12 inches.

3. Lay the cut tubing on the floor. Support it on a concrete block to get proper height and clearance from the ground for easy welding. Arrange the pieces of tubing according to your sketched go-kart design or using the drawing on the ground as a blueprint. Weld the pieces together using a MIG or MMA/stick welder.

4. Bend the right and front sides from one length of the tubing using your pipe bender. Bend the body and roofing tubing to create round edges based on your design to be sure that all parts are equally measured.

5. Install your front A-Arms assembly. A-arm, also known as control arm or wishbone is a component of vehicle’s suspension system that manages how the wheels rotate in relation to the vehicle’s body. Refer to your design to guide you on the shape and size of the A-Arm. Place an order for a proper control arm assembly, using your kart’s design, from your local car dealer. Position you’re A-arm’s upper control arm to the body and cross-member of your kart, and weld them together at their points of contact.

6. Install the front stub axles and king pins. Weld the steering arm to the top of the king pin (“n”-shaped pieces) at an angle of 110 degrees. Weld the sub axle onto the side of the king pin. Attach the front stub axle and the king pins to the chassis with your 0.5-inch high-tension bolts, lock nuts and washers. Check that both of the front stub axles are at pivot. The axles should swivel freely or move from side to side.

7. Tie the steering arms with the tie rods; insert the outer into the inner tie rod shaft and screw it on. Position the tie rod end ball joint into the spindle mount, and tap it gently with a hammer to seat it into place. Slip the nut into the stud and attach the stud into the steering arm. Tighten the nuts to secure it place with your end wrench. Attach cotter pins on the tie rod end. Put a lock nut on the inner tie rod shaft and tighten to fasten the tie rod end in place.

8. Install the rear axle carrier to the chassis. Weld your 47-inch long 8-millimeter steel plate to the chassis for bolting the bearings onto. Squeeze the bearing with your triangular pressure plate to secure the outside rim of the bearing tightly while permitting the inside rim to rotate at the same time. Squeeze either side of the bearing using high-tensile 0.3-inch-diameter steel bolts. Secure them with lock nuts and washers. Alternatively, purchase pillar bearings that bolt easily onto the chassis. Bolt them to the chassis using the bolts and nuts provided.

9. Fabricate the rear axle. The rear axle should have keyways -- a metal bar or rod that stops the wheels or sprocket from spinning freely on the axle. Cut two metal tubing -- measuring 1.57 inches diameter, 0.98 inches long -- using your hacksaw. Weld them directly onto the axle. Weld the hubs of the wheels and the sprocket carrier directly to the rear axle.

10. Install the brakes. Position the brake rotor against the brake disk and trace the positions for drilling holes to the disc using your marker. Drill bolt holes into the brake disc and the sprocket to create holes for the bolts. The number of holes drilled will depend on the holes on the brake rotor. Place the brake disc onto the rear axle. Attach the brake calipers or shoes to the chassis. Secure the calipers using support brackets to prevent them from rotating. Place the brake lever to the chassis close two inches away from the calipers on the rear axle.

11. Place the hub directly onto the rear axle, and bolt it or weld it up into place. Place the brake rotor on the hub and screw it on. Screw on the caliper bracket over the brake rotor. Slide the pads back over the rotor and fasten the caliper using caliper pins. Torque the pins into place. Slip the axle nut onto the axle and torque into place. Mount the wheels onto the axle and torque the nuts to secure them into place.

12. Hire a professional mechanic to install the 2-stroke motorcycle engine at the back of the go-kart on the right of the driver. Engine parts need to be professionally fitted, steel frames be cut and drilled onto, which require expertise since mistakes here can be deathly. The engine should supply an average of 8 horsepower.

13. Have the mechanic connect the steering system and steering wheel to the axle system and the wheels. Also, have him install headlights and components such as the centrifugal clutch and the torque converter.

14. Bolt your bucket seats onto the go-kart's floor. To determine the right location, position them at the front and sit on them to ensure that enough room is left for the pedals, seat and steering wheel.

15. Paint the go-kart in your preferred color and allow it to dry overnight. Test your kart in a lonely secure road. Correct any imperfections before you consider riding it on a public road.

References

• Kartbuilding: Go-Kart Design
• "Speed With Style" Racing: What Is a Shifter Kart
• CRG-America: Kart Tuning Manual