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KartFab

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http://KartFab.com/go-kart-plans

Go Kart Plans - Two Seat Go Kart

Contents

• Parts, Tools, and Materials Needed
• Plate Cuts
• Go Kart Base Frame
• Bumper
• Go Kart Axle
• Floor Pan
• Motor Mount
• Seat Frame
• Seat Slider Brace....................................................................................................................................
• Steering
• Spindle Brackets
• Brake and Throttle Pedal Stop Tabs
• Brake Band Stud
• Brake Rod Guide Tab
• Brake Rod
• Throttle Cable Guide Tab
• Side Rails
• Foot Rest
• Paint......................................................................................................................................................
• Final Assembly.......................................................................................................................................
• Final Kart Additional Views

Plans are copyrighted. Feel free to share the free go kart plans for personal use, write about, and link to http://kartfab.com/go-kart-plans. Build and drive the go kart at your own risk.

LEGAL

KartFab, LLC is the sole creator and owner of these free go kart plans. KartFab, LLC is the original and only source of these plans. KartFab, LLC does not authorize these plans to be resold or redistributed in any form or modification hereafter. This PDF go kart plan is copyrighted. KartFab, LLC does not authorize resale, or redistribution in any form. Access to http://kartfab.com is complimentary. Unapproved use of images, text, documents, or any content on http://kartfab.com is prohibited.

Plans user (you) releases, discharges, and relinquishes all liability from KartFab, LLC when downloading plans, 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.

SAFETY

SAFETY WHEN BUILDING: Wear proper PPE and use appropriate work practices when performing hot work. Ear protection, leather gloves, welding helmet, face shield, welding clothes, and safety glasses are the 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, kill switch, 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 from running into things because you didn't brake, weren't familiar with the go kart, or lost traction around a corner. You can throw a rider off of the kart by swerving or even turning unexpectedly. It is best for the passenger to put his or her left arm on the backrest, and right hand on the side rail to avoid slipping off around corners. While the center of gravity of the go kart is very low, the possibility of flipping when turning exists. Slowly turn the wheel while driving at a significantly reduced speed when turning. The engine, especially muffler, is hot. Avoid touching it. Loose clothing (e.g. scarves), long hair, and fingers can 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-4tsOc Shows an overview of the go kart driving. Webpage http://kartfab.com/go-kart-plans

Parts, Tools, and Materials Needed

Video: Go Kart Materials https://youtu.be/VRYZr0223vk Materials and tools used in the build. Webpage http://kartfab.com/go-kart-plans/go-kart-materials

Bulk Steel Materials - buy at steel yard Quantity 3/16" plate (12"x12" section) 1 11ga 1"x1" sq tubing (10 ft section) 5 16 ga sheet metal (26"x20" section) 1 11ga 3/4" round tubing (18" section) 1 1"x1"x1/8" angle iron (1" section) 1 3/8" round bar (36" section) 1 1/4" round bar (72" section) 1

Go Kart Parts Kit click here Quantity 140/70-6 knobby tires 4 6" rims 3 6" drive wheel with hub 1 5/8" ID 1 3/8" OD sealed bearings 8 60T drive wheel sprocket 420P 1 3/4" bore 10T centrifugal clutch 420p 1 4" brake drum 1 3/16" x 1/2" keystock 1 4" brake band 1 throttle cable (manco) 1 manco throttle return spring 1 manco brake return spring 1 heavy duty gas/brake pedals (L+R pair) 1 kill switch (1/2") 1 steering wheel 1 3/8 x 8" tie rod w/ tie rod ends 1 3/8 x 18" tie rod w/tie rod ends 1 spindle (L+R pair) 4" center to center 1 3" spindle bracket w 1/2" kingpin holes 2 seat slider (8" mounting pattern) 1 motor mount plate 1 420p chain 1 420p master link chain connector 1 bench seat 1

Tools Needed - buy at hardware store welder angle grinder drill tape measure protractor/square angle finder level razor blade hammer

Video: How To Cut Steel https://youtu.be/Ob-IVdh3Qm Shows how to measure and cut steel. Webpage http://kartfab.com/go-kart-plans/4-ways-cut-steel-go-kart-frame

Plate Cuts

Below 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 is just an example of how to arrange everything to be cut. I left a 1/8" gap between parts. You can trace out the dimensions on a piece of steel with a razor blade and a straight edge. Holes can be started with a center punch and drilled out. Exact dimensions and orientation of each part are found where the part is needed in the plans.

Note: Seat sliders may come in 11" bolt to bolt, or 8" bolt to bolt patterns. The above diagram assumes 8" sliders will be used.

Note: Chop saws measure 0 degrees at 90 degrees actual (a flat end cut), and protractors measure actual angles of cuts. Both chop saw degree and protractor degree measurements are included in plans.

Go Kart Base Frame

Cut out your 1"x1" steel tubing into the base frame, and weld it together. The bottom corners are cut on 45 degree angles.

Video: Go Kart Axle https://youtu.be/iyzcepB8Kh Shows how to fabricate the axle and weld it to the kart. Website http://kartfab.com/go-kart-plans/homemade-go-kart-axle

Go Kart Axle

Cut out a 25 3/16" section of 1"x 1" square tubing, and weld 5/8" bolts to each end. The 6" bolt goes on the 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 Pan https://youtu.be/D43W7X_3B4E Shows the welding of the floor pan to the go kart frame. Webpage http://kartfab.com/go-kart-plans/go-kart-floor-pan

Floor Pan

Weld the 16 ga sheet metal underneath the base frame, drilling two holes through which a bolt will be inserted to a seat slider. Floor pan dimensions are 26"x 20".

Video: Go Kart Seat Install https://youtu.be/hNJgy8tpCc Shows how to build the seat frame for the seat and sliders. Webpage http://kartfab.com/go-kart-plans/go-kart-seats-how-to-make-vs- buy-cheap

Seat Frame

The 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 seat frame, cuts are made at 37.5 degrees (chop saw measurement) or 52.5 degrees measured from a protractor 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, extend the seat frame bottom by 3", and add two additional mounting brackets to accommodate the longer slider.

Seat Slider Brace

Weld 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) is 10"x 2 3/4"- 8" between holes. the brace for 11" sliders would be 12"x 2 3/4" -11" between holes.

Next, create the steering hoop and kill switch brace. Cuts are made at a 39 degree angle (chop saw) or 51 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 Brackets

Center and weld the spindle brackets to the front axle. No camber or caster is built into this kart, and it steers well.

Note: If you upgraded to front spring suspension brackets (springer), you should center the bracket left to right. However, the longer bracket should not be centered up/down. 1" clearance from the bottom of the bracket to the bottom of the front axle is recommended.

Video: Go Kart Brake System https://youtu.be/BhRFXiK2UYY Shows how to install brake band, rod, return spring, and brake pedal. Webpage http://kartfab.com/go-kart-plans/go-kart-brake-band

Brake Band Stud

Weld the 3/8" round bar to the frame. This stud will serve as the pivot for the brake band.

Brake Rod Guide Tab

Weld this tab to the kart with the brake rod already bent and inserted. Fine adjustments may be made with the brake band installed by bending the rod itself.