Things You'll Need:
- Chalk
- Measuring device
- Angle iron
- Tube notcher
- Welder
- Filler material
- Harbor Freight pipe bender
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Step 1
Sit down on the floor, picture yourself in your Go Kart and draw with chalk the measurements that are comfortable for your legs. Usually frames have a width of one third to two thirds the size of the frame at the wheel base to fit two riders. A wider wheel base creates better stability so it doesn't tip over.
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Step 2
Cut the metal tubing first with a chop saw, and then lay out the frame to see how it looks.
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Step 3
Weld round to round tubing using a tubing notcher. The round tubing where your feet rest has to be wedged accurately to the tubing, so that the pieces are joined solidly together, a process called "fishmouthing."
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Step 4
Connect round to square by sawing the round tubing flat and welding it to the square. Another option is to heat the end of round material and hammer it flat.
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Step 5
Use round tubing to install a roll bar in front and over the rider's head to prevent injury in case of an accident. Customize the frame and seating arrangement from 2 inches off the ground to ensure a solid center of gravity, so the Go Kart doesn't flip over.
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Step 1
Use angle iron for the entire frame, or just for parts of the kart that you need to bend into angles. Use Step 1, Section 1 to create the basis of your frame.
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Step 2
Saw off one side of the iron, and then heat and bend as necessary.
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Step 3
Weld after reaching the desired shape through heating and bending. Reinforce the frame by adding filler material.
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Step 4
Decorate your frame with bends using a Harbor Freight pipe bender.
