Go Kart Plans - Two Seat Go Kart - KartFab

KartFab.comGo Kart Plans - Two Seat Go Karthttp://KartFab.com/go-kart-plans

ContentsParts, Tools, and Materials Needed . 5Plate Cuts . 7Go Kart Base Frame . 8Bumper . 9Go Kart Axle . 10Floor Pan . 11Motor Mount . 12Seat Frame . 13Seat Slider Brace. 14Steering . 15Spindle Brackets . 17Brake and Throttle Pedal Stop Tabs . 18Brake Band Stud . 19Brake Rod Guide Tab . 20Brake Rod . 21Throttle Cable Guide Tab . 22Side Rails . 23Foot Rest . 24Paint. 24Final Assembly. 24Final Kart Additional Views . 25

Get the exact parts kit needed to build this go kart.Go Kart Parts Kit Link- http://kartfab.com/go-kart-plans -Click then "buy fixed axle go kart parts kit"Go Kart Plans Overviewhttp//kartfab.com/go-kart-plansHow to Build The Go Kart:YouTube Video Playlisthttps://www.youtube.com/playlist?list PLzJ0LQjPgipfr9mDUN1PEpkcigEcKjuxKFollow KartFab on Social MediaYouTube: www.youtube.com/c/KartFabTwitter: http://Twitter.com/KartFabFacebook: https://Facebook.com/KartFabGoogle : https://plus.google.com/ KartFabInstagram: https://instagram.com/kartfab/

Plans are copyrighted. Feel free to share the free go kart plans for personal use, write about, and link tohttp://kartfab.com/go-kart-plans. Build and drive the go kart at your own risk.LEGALKartFab, LLC is the sole creator and owner of these free go kart plans. KartFab, LLC is the original andonly source of these plans. KartFab, LLC does not authorize these plans to be resold or redistributed inany form or modification hereafter. This PDF go kart plan is copyrighted. KartFab, LLC does not authorizeresale, or redistribution in any form. Access to http://kartfab.com is complimentary. Unapproved use ofimages, text, documents, or any content on http://kartfab.com is prohibited.Plans user (you) releases, discharges, and relinquishes all liability from KartFab, LLC when downloadingplans, builds, and drives or allows others to drive the go kart. KartFab, LLC retains indemnity, is saved,protected, and held harmless from all forms of liability from the use of these plans. Plans user (you)assume all responsibility and liability from the moment you view, share, and/or use the plans.SAFETYSAFETY WHEN BUILDING: Wear proper PPE and use appropriate work practices when performing hotwork. Ear protection, leather gloves, welding helmet, face shield, welding clothes, and safety glasses arethe minimum amount of PPE you should wear when making the kart.SAFETY WHEN RIDING: Go karts are not full size automobiles, and should not be driven on public roads.Automobiles may not see you, and run you over. Always wear a helmet. Inspect and test the brakes, killswitch, and all nuts and bolts prior to riding. Familiarize yourself with the kart before driving faster.Knowing the difference between the brakes and the gas is a huge deal. Accidents can occur fromrunning into things because you didn't brake, weren't familiar with the go kart, or lost traction around acorner. You can throw a rider off of the kart by swerving or even turning unexpectedly. It is best for thepassenger to put his or her left arm on the backrest, and right hand on the side rail to avoid slipping offaround corners. While the center of gravity of the go kart is very low, the possibility of flipping whenturning exists. Slowly turn the wheel while driving at a significantly reduced speed when turning. Theengine, especially muffler, is hot. Avoid touching it. Loose clothing (e.g. scarves), long hair, and fingerscan get caught in chain, sprockets, and axles. Use common sense. It is up to YOU to be safe.Video: Go Kart Build (Free PDF Plans)https://youtu.be/YPdat-4tsOcShows an overview of the go kart driving.Webpagehttp://kartfab.com/go-kart-plans

Parts, Tools, and Materials NeededVideo: Go Kart Materialshttps://youtu.be/VRYZr0223vkMaterials and tools used in the art-materialsBulk Steel Materials -buy at steel yard3/16" plate (12"x12" section)11ga 1"x1" sq tubing (10 ft section)16 ga sheet metal (26"x20" section)11ga 3/4" round tubing (18" section)1"x1"x1/8" angle iron (1" section)3/8" round bar (36" section)1/4" round bar (72" section)Go Kart Parts Kit click here140/70-6 knobby tires6" rims6" drive wheel with hub5/8" ID 1 3/8" OD sealed bearings60T drive wheel sprocket 420P3/4" bore 10T centrifugal clutch 420p4" brake drum3/16" x 1/2" keystock4" brake bandthrottle cable (manco)manco throttle return springmanco brake return springheavy duty gas/brake pedals (L R pair)kill switch (1/2")steering wheel3/8 x 8" tie rod w/ tie rod ends3/8 x 18" tie rod w/tie rod endsspindle (L R pair) 4" center to center3" spindle bracket w 1/2" kingpin holesseat slider (8" mounting pattern)motor mount plate420p chain420p master link chain connectorbench 1Tools Needed - buy at hardware storewelderangle grinderdrilltape measureprotractor/squareangle finderlevelrazor bladehammer

Nuts and Bolts5/8-11 x6" bolt5/8-11 x4" bolt5/8-11 nut1/2-13 x 3 1/2" bolt1/2-13 nut3/8-16 x 2" bolt3/8-16 x 1" bolt3/8-16 nut5/16-24 (fine thread)x 1 1/4" bolt5/16-18 serrated flange nut5/16-18 x 2" bolt5/16-18 nut5/16-18 x 1 1/2" boltQuantity114221231421881/4-20 nut101/4-20x1 1/2" bolt1/4-20 x 1 1/4" bolt1/4-20 x1" bolt1/4-20 x 1/2" bolt4153Misc materials5/8 machine bushing5/8 x 1" spacer1/8" cotter pin5/32" cotter pin3/8 x 1 1/4" clevis pin (oruniversal)2 1/2" OD Flat Washer5/16" washer5/16" fender washer1/4 ID 3/8"OD x1/2" steel spacermale bullet connectorthread locker (blue)black paintframe paintprimer3/4" ID x 1" spacer4 1/2" angle grinder wheelsQuantity4211114111114227Goes Where?driver side dead axlepassenger side dead axlefront spindles, dead axlespindle bracketsspindle bracketspitman armL R spindlespitman arm, L R spindlesmotor shaftmotor mountbrake and throttle pivotbrake and throttle bolts (2), seat slider (8), drive wheel (8)motor mount(4), drive wheel assembly (4)steering wheel (3), kill switch ground (1), brake pedal (3)throttle pedal (3)seat bottomthrottle pedal (top hole)brake pedal (2), throttle pedal (1), seat back (2)steering wheel (3), kill switch ground (1),Goes Where?front spindles, dead axlefront spindlesbrake band clevis pinbrake band welded stubbrake bandsteering wheelunder seat slidermotor shaftthrottle cable eyeletkill switchall nutswheels3 for frame, 1 for wheels and seat backframe/wheels, seat backsteering shaft4 cut off, 1 sanding, 1 grinding, 1 wire wheel

Video: How To Cut Steelhttps://youtu.be/Ob-IVdh3Qm0Shows how to measure and cut ys-cut-steel-go-kart-framePlate CutsBelow is a diagram of the 1' x 1' x 3/16" piece of steel you will use to make all of your plate cuts. This isjust an example of how to arrange everything to be cut. I left a 1/8" gap between parts. You can traceout the dimensions on a piece of steel with a razor blade and a straight edge. Holes can be started with acenter punch and drilled out. Exact dimensions and orientation of each part are found where the part isneeded in the plans.Note: Seat sliders may come in 11" bolt to bolt, or 8" bolt to bolt patterns. The above diagram assumes8" sliders will be used.Note: Chop saws measure 0 degrees at 90 degrees actual (a flat end cut), and protractors measureactual angles of cuts. Both chop saw degree and protractor degree measurements are included in plans.

Go Kart Base FrameCut out your 1"x1" steel tubing into the base frame, and weld it together. The bottom corners are cut on45 degree angles.

Video: Weld Go Kart Framehttps://youtu.be/rRUfEsNbzNQShows how to weld frame and bumper o-kart-frameBumperCut out pieces for the bumper, the 'rounded edges' are cut on 22.5 degree angles (chop sawmeasurement) or 67.5 degrees measured from a protractor.Drill 5/16" centered holes through the tubing at 1 1/8" from the end of the tubing for brake/gas pedals.

Video: Go Kart Axlehttps://youtu.be/iyzcepB8Kh4Shows how to fabricate the axle and weld it to the ade-go-kart-axleGo Kart AxleCut out a 25 3/16" section of 1"x 1" square tubing, and weld 5/8" bolts to each end. The 6" bolt goes onthe driver side of the kart, and the 4" bolt goes on the passenger side of the kart.Weld the axle underneath the base frame 7" from the inside edge of the rear of the kart frame.

Video: Go Kart Floor Panhttps://youtu.be/D43W7X 3B4EShows the welding of the floor pan to the go kart art-floor-panFloor PanWeld the 16 ga sheet metal underneath the base frame, drilling two holes through which a bolt will beinserted to a seat slider. Floor pan dimensions are 26"x 20".

Video: Go Kart Engine Mounthttps://youtu.be/66mZYlWIinAShows how to properly line up the clutch, sprocket, and kart-engine-mountMotor MountWeld the motor mount to the frame as the last step to ensure the engine clears the seat frame. Nodimensions are included deliberately as you will need to line up the engine with sprocket and clutchinstalled. Add the clutch to the engine shaft, and assembled drive wheel to the axle stud. Line up theclutch teeth to the sprocket teeth with chain installed. Make sure the motor mount slots allow for theengine to slide forward, then tack the mount into place. Final welding of the motor mount should beperformed as the final step of the kart build. 5/8" and 3/4" washers or spacers may be used to fine tunethe alignment on either the engine shaft for the clutch, and/or the dead axle stud for the wheelassembly.

Video: Go Kart Seat Installhttps://youtu.be/hNJgy8tpCc0Shows how to build the seat frame for the seat and -kart-seats-how-to-make-vsbuy-cheapSeat FrameThe seat that comes in the go kart kit does not bolt onto the kart itself, rather a frame you will make.The frame is then bolted to seat sliders. The seat sliders are then bolted to the frame. For the seatframe, cuts are made at 37.5 degrees (chop saw measurement) or 52.5 degrees measured from aprotractor for a 105 degree incline from bottom to backrest.Note: If you have 8" bolt pattern seat sliders, use the above diagram. For 11" bolt pattern sliders, extendthe seat frame bottom by 3", and add two additional mounting brackets to accommodate the longerslider.

Seat Slider BraceWeld two braces to the sides of the go kart frame that will allow the seat slider to bolt to the frame.Note: Seat slider plate should match seat slider bolt spacing (e.g. some seat sliders come in 8" or 11",extending brace is necessary for 11" sliders. For example; the brace for 8" sliders (pictured below) is10"x 2 3/4"- 8" between holes. the brace for 11" sliders would be 12"x 2 3/4" -11" between holes.

Video: Go Kart Steering Systemhttps://youtu.be/7IxDPuaDyw4Shows how to assemble the go kart steering kart-steeringSteeringCut out an 18" section of 3/4"x11ga tubing and weld together the steering tabs. The pitman arm,1"x1"x1/8" angle iron, tab that will hold the shaft to the frame, and spacer are picture below.Next, insert the additional 1" spacer (you may need to grind the shaft near the steering hoop for a loosefit). Drill a 3 hole pattern onto the flat washer (the one that fits your specific steering wheel), and weldthe washer to the end of the shaft.

Next, create the steering hoop and kill switch brace. Cuts are made at a 39 degree angle (chop saw) or51 degree angle (protractor) for the hoop.Next, verify all measurements are correct. The hoop and shaft should be at a 90 degrees to each other.

Spindle BracketsCenter and weld the spindle brackets to the front axle. No camber or caster is built into this kart, and itsteers well.Note: If you upgraded to front spring suspension brackets (springer), you should center the bracket leftto right. However, the longer bracket should not be centered up/down. 1" clearance from the bottom ofthe bracket to the bottom of the front axle is recommended.

Brake and Throttle Pedal Stop TabsThese tabs are used to keep the brake and throttle pedals in their resting position, and full forwardpositions.

Video: Go Kart Brake Systemhttps://youtu.be/BhRFXiK2UYYShows how to install brake band, rod, return spring, and brake art-brake-bandBrake Band StudWeld the 3/8" round bar to the frame. This stud will serve as the pivot for the brake band.