Golf carts are not complex vehicles. You can build your own if you have the right materials and skills. You will need to build a frame, add and tune the motor system, then finish with interior design. The process may take several days. Since you are building your cart for comfort and mobility it is recommended you pay particular attention to the type of engine you choose and the seats construction.
Things You'll Need
- 1 4-by-6 foot stainless steel board
- Metal saw
- 4 1-by-2 foot stainless steel boards
- Metal bender
- Welding tools
- Motorcycle engine
- Socket wrench set
- Hex keys
- 4-foot drive shaft with a chain gear
- 2-foot stainless steel pole
- Lever arm with steering wheel
- 4-foot drive shaft
- 4 wheels
- 2 symmetrical connecting rods
- 2-by-4 foot stainless steel board
- Double passenger leather seat
- 2 2-by-6 foot stainless steel boards
- 4-by-4 foot stainless steel board
- Accelerator pedal
- Brake pedal
- 4 4-foot metal poles
- 4-by-6 foot piece of canvas
- 3 1-by-4 foot stainless steel boards
Lay the 4-by-6 feet stainless steel board on the ground. Cut 1/2 foot into the frame perpendicular to the side at the 1-foot mark on each of the back of the longer sides. Make a similar cut one foot closer to the front and connect the cuts so there are two holes for the wheels. Make another two similar holes 1/2 foot from the front to 1 1/2 foot feet from the front.
Bend the 1-by-2 foot stainless steel boards 1/2 foot from both sides by 90 degrees with the metal bender. Cut the sides of the boards halfway across from one side so each side consists of two flaps. Cut at the bend until one flap from each side is removed. Make sure that the two flaps are on the same side. Use the metal bender to bend the top board without sides down by 90 degrees to form a wheel cover. Weld the sides together. Do this to each of the four boards and weld each of them to the holes on the frame board along the edges. Drill a hole roughly at the center of the wheel covers at the sides for the drive shaft to go through. Cut a 1-inch wide slot around 1-foot tall in the right rear wheel cover facing the front.
Disassemble the old motorcycle engine by unbolting all the necessary bolts with wrenches and hex keys and lay it near the rear right wheel cover. Feed the chain from the motor through the slot in the wheel cover and pull it so that it is 1/2 inch past the hole you drilled. Hold the motor down and mark where the bolts go downwards. Drill through the bottom frame and bolt the motor on. Remove the gas tank from the motorcycle and bolt it down right next to the engine. Route the gas line from the engine to the gas tank and connect it. Connect the motor to the controller from the motorcycle and route the accelerator and starter to the front of the vehicle.
Insert the geared drive shaft through the two holes in the back wheel covers. Hook the chain over the shaft and pull it tight against the gears. Install the wheels on to the ends of the shafts.
Weld the 2-foot stainless steel pole one foot from the front of the frame at the center. Drill a 2-inch hole at the top of the pole and push the lever arm through with the steering wheel at the top. Insert the drive shaft through the front two holes and install the wheels at the ends. Connect the wheels to the lever arm with symmetrical connecting rods.
Weld the 2-by-4 board to the front vertically. Weld the two 2-by-6 boards to the sides vertically, perpendicular to both the front board and the bottom boards. Use the metal cutter to cut a 2-foot section one foot from the front to three feet from the front to serve as entrances and exits to the vehicle. Weld the 2-by-4 board to the back vertically to form the back. Weld the 4-by-4 board to the back of the vehicle. Cut a 2-by-1 inch hole right above the gas tank and the motor. Bolt the hinges to the bottom of the back of the seat and bolt the hinges right behind the hole. This allows you to flip the seats back to fill the gas tank.
Drill and bolt the accelerator pedal six inches from the center of the vehicle and connect the accelerator line to the pedal. Route the starter along the floor and up the front board to the space right behind the steering wheel. Install a brake disk at the front wheels and route it to the space left of the accelerator pedal. Plug the lines into the brake pedal. Drill holes as needed and bolt the brake pedal into the floor of the vehicle.
Drill a 2-inch hole in each of the vehicle's back corners. Weld two of the 4-feet poles into the holes. Weld the other two poles at the front corners vertically. Tie the canvas roof to the top of the poles to serve as a roof of the cart. Weld one of the 1-by-4 boards to the back of the vehicle vertically and the other two at the sides connecting to it. This serves as a cargo space.
Tips & Warnings
- Only attempt to do this if you are comfortable working with brake systems, fuel systems and old engines.
- Photo Credit Jupiterimages/Photos.com/Getty Images
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