There's no better way to channel your speeding mischief than to ride a go-kart. Making your own gokart by following a predefined plan or designing your own will be addictive. This activity is fun for amateur mechanics of all ages. You can learn to design your own go-kart, build the chassis, and add cool details, depending on the availability of your tools. See Step 1 for more information.
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Method 1 of 3: Planning Your Project
Step 1. Draw the design of the kart you want
Go-karts can be made in a variety of sizes, shapes, and designs. This homemade vehicle is very flexible with any design element you want to add to it. The basics you will need are a chassis, a simple engine and a steering/braking system.
- Activate your creativity and create detailed diagrams to ensure you have the materials needed to complete this project. Check out other go-karts for inspiration and learn from the go-kart makers.
- Alternatively, you can search online for many schemes and designs for different go-kart models. This can be done if you choose to use someone else's design. Use an existing design and make modifications if necessary.
Step 2. Determine the right size of the gokart
The size of the go-kart will depend on the age and size of the driver. For young drivers, the go-kart should measure approximately 0.76 meters in width and 1.3 meters in length. For an adult driver, the go-kart should be around 1 meter wide and about 1.8 meters long.
Plan the manufacture of the go-kart accurately with specific measurements. This is very important, because if you don't, it will be difficult to get the ingredients you need in the required quantities
Step 3. Gather the ingredients
If you don't have a lot of money, visit a thrift store and look for cheap ingredients. Or, if you can strip down certain parts of an old lawn mower/gokar that don't work anymore, you can. Ask a handyman to dismantle these parts and the 4 cylinder engine (with horsepower ranging from 10-15 HP), the handlebars and the clutch system. Here's what you'll need:
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To make the chassis:
- 9.2 meters tuba box diameter 2.5 cm
- 1.8 meters round steel rod 2 cm in diameter
- 1.8 meters round stalk 1.5 cm diameter
- A 0.5 cm thick steel plate with a length and width that slightly exceeds the size of your machine
- Plywood or metal (for the bench and go-kart floor)
- Seat
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For the engine:
- Engine (try to use motor from lawn mower)
- Chain with the right size
- Bolts and rings
- fuel tank
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For steering system:
- Wheel
- steering wheel
- Gears and handbrake
- Steering stick
- Drive bearings (bearings)
- Steering gear
- Brake pedal
- Starter system
Step 4. Prepare the welding machine
If you have never welded before, hire a welder. The most important thing in building a go-kart is to build a solid chassis so that it can withstand the weight of the go-kart while you are driving and starting the engine. If you wish to weld the chassis with steel rods, the welding must be carried out with sufficient heat and depth and in alignment. Otherwise, the weld will be weak, brittle, cracked, and only effective on the surface. This can jeopardize your safety.
If you don't have welding experience, don't build a gokart. Learn first by doing simpler projects
Step 5. Consider purchasing a ready made kart design
If you're not interested in welding and designing your own gokart, buy a go kart ready to install. A go-kart like this one will provide in-depth instructions and schematics on how to set it up without the need for a welding tool (you only need simple tools).
Go-karts like this can be purchased for around 6 to 7 million rupiah, and you'll have the satisfaction of putting together a go-kart without having to go through the trouble of designing and buying all the materials separately
Method 2 of 3: Building the Chassis and Steering System
Step 1. Cut the metal tubing
Adjust the length to your design or scheme.
- In general, the front will be curved and narrower than the rear, so there will be enough room for the wheels to turn. In this way, the chassis is also more flexible so it is not easily damaged. To make the design, install the King Pin bolt on the front corner where the wheel will be. This bolt will make it easier to turn the wheel.
- To make the manufacturing process easier, mark the floor of the garage/area where you are working with chalk. Adjust to the size of your design. You can even draw the whole design and start creating go-karts on top of the drawing.
Step 2. Start welding the frame based on the design you made
Use cement blocks to raise the frame as you work, so you can make sure all connection points are solid and the chassis is secure. This chassis must be strong enough to withstand the weight of the driver and engine, so don't be careless. Use gussets (small steel plates) to strengthen all the corners.
Step 3. Install the front axle
Build your axle using straight steel rods 2 cm long, and two washers that attach to your go-kart frame. Use washers and dowels to ensure the axle stays in place.
Make sure the front axle is flexible enough so that you can turn the go-kart easily. Do this before moving on to the steering system section and attaching the King Pin bolts to the steering arm on the chassis. You'll need to have at least a 110 degree wheel turning limit on the front, so plan this carefully
Step 4. Install the rear axle and wheel
You may have to mount the axle holder using bearing housings, which means the axle itself can be welded to the go-kart frame, but still give the go-kart the ability to turn smoothly. Weld the steel plate to the chassis. Secure the installation by using strong bolts and nuts to keep it in position.
You can buy these components instead of making your own. Sometimes these components are called "Pillar Bearing Units"
Step 5. Make the floor and the base of your seat from plywood or metal
You can get both of these materials from the seat of an old go-kart or an appropriately sized old car. This will help you not to overspend. You can also make your own, by providing a pillow for the seat. Make room for the steering system and other controls.
Method 3 of 3: Installing the Engine and Steering System
Step 1. Install the engine bolt
Weld a thick metal plate (with a thickness of 0.5 cm) and flat onto the back frame to mount your machine. Place the engine on this plate, and prepare the holes for attaching the engine bolts. Adjust so that the steering system on the axle is connected to this machine.
Install the steering system on the axle before connecting the axle to the ring. You can use long bolts to do this, or weld them directly to the axle, straight and parallel to the bolts on your machine
Step 2. Set up your steering connection system
Use a 1.5 cm diameter steel rod for the connection, and a 2 cm diameter steel rod for the axle. To bend this 2 cm diameter stem, use a heater, then bend it so that it forms a 90 degree angle.
Provide flexible joints to adjust the steering system, as this is necessary to give the steering system the ability to turn and turn: adjust the vertical level of the front wheels and steering turns
Step 3. Install the wheels and brakes
Choose a small racing wheel to produce a gokart with optimal acceleration and control. Attach these two components to the axle at the base of the wheel and start taking care of the braking system, so your kart will be safe to drive.
- Attach a disc to the rear axle and a caliper array to the chassis for the best possible system. You can find working calipers from used motorcycles, in the right size for your go-kart. This will make your job easier.
- Install the brake pedal for the foot. Whatever type of acceleration system you use, install a foot brake system. Make sure your hands stay in control of the steering wheel as much as possible.
Step 4. Attach the control cable to the hand starter
You may be able to attach it to a foot pedal as well, but this will depend on your experience and the type of machine you are using. To make it even easier, attach it to a hand starter and you can control it just like you would a lawnmower.
Step 5. Double-check your suspension and braking system before attempting to ride a go-kart
If you are driving at a low speed, make sure you don't feel any problems with your axle in the first lap. Check the performance of your welds, brakes and engine. Then start having fun!
Tips
- Add extra parts on final finishing, so you can finish all the bigger and more important mechanical parts first.
- The acceleration system can be connected to a starter cable from an unused lawn mower, or to the foot accelerator pedal.
- This go-kart utilizes a centrifugal clutch, but modifications can be made by incorporating a steering belt system and a hand/foot controlled gas pedal/clutch.
- Check out the go-kart manual for tips on how to ride and maintain your go-kart.
- Some people suggest buying certain systems that have been designed by engineers and tested, such as Ackermann steering system, Castor, King Pin inclination, etc. It will be easier for you to finish your go-kart, and enjoy your ride more if you decide to use these systems.
- The cost required to make a go-kart ranges from at least Rp.700,000, - to Rp.900,000, maybe more. You can buy a nice set of designs for around Rp. 500,000,-. Some of the other designs are even cheaper. Planning costs are usually a little under Rp. 1.000.000, -. Maybe you're better off going this way if you're not a professional.
- The above note is based on the consideration that you are using "used" parts from lawn mowers or other sources that are no longer used. It will most likely be cheaper for you to buy a factory go kart than it is to buy specialized components to build your own kart.
Warning
- Test your go-kart before driving it on the track, as parts may come loose or fail to work.
- Use safety equipment when driving a go-kart: helmet, elbow/knee protectors, etc.
- Go-karts are not real cars and should not be driven on public roads!
- Since this is a simple project without deep technical and design considerations, it is best not to use high gear ratios or large engines. Gokart speeds that exceed 16-24 km per hour can cause existing components to fail.
