How to build a go kart with the lowest budget

ByThe Old Racer
Table of contents

If you’re one of those people who really love to assemble things, go ahead and learn how to build your own go-kart from scratch, and remember to buy every spare part when hunting for the best price.

What should you prepare?

How to build a go kart

An alternative to buying your own tools is to have an automotive shop fix the parts as needed. It might be costly, but it’s a real time-saver. You don’t have to clean the mess inherent in fixing your own parts, and you won’t make noises that often annoy neighbors.

You’ll need a private area for your project. That location should be dry, spacious, and well-lit, with a hard floor. You’ll also be focusing on this task for between three and six months, so an area of your garage is a natural choice.

So, are you truly prepared to construct your own go-kart? Let’s get started by gathering the necessary spare parts.

How to build a go kart in 5 Step

Step 1: Front A-arms assembly

  • Always measure your steel bars twice to ensure that the length specified is correct. Welded pieces should never be used for the primary support parts.
  • Make sure the form of the A-Arm is precise and completely equal by using a pattern, template, or guide.
  • Thoroughly link all intersections and pieces together. While welding, use steel grips to hold your pieces steady.
  • When locking bolts, use the proper size nuts and remember to put a washer between each of them. To avoid warping and wear, weld the tails of steel tubes.

Step 2: Mainframe assembly

  • Place the steel pipe on a clear area of your floor. Before welding each piece, make sure to measure its length and width.
  • Use proper support to ensure a suitable height and clearance of welded parts.
  • To achieve round edges, the main part and roofing frame must be bent. Make use of a pattern to ensure that all arches are measured equally.
  • Arrange the seats in their selected locations to determine the final size of your kart.

Step 3: Steering system assembly

  • Stabilizing the steering part to the frame by pushing the steel clips into the bored holes of the pipe steel.
  • Use nuts and bolts when needed.
  • Refer to some professional models of the steering rack (1986 Hyundai Excel for example)

Step 4: Drive axle assembly

  • Locate a lawnmower differential that has a 13-tooth sprocket and a 9-tooth axle.
  • Connect them with a 50 chain type to increase the speed beyond what the lawnmower could previously provide. And installing a guard to prevent it from slipping off the vehicle while it is running.
  • Select the proper size of gearboxes and wheels to ensure proper operation.

Step 5: The “guts” of the go-kart

  • To ensure compatibility, purchase accessories alongside the engine. 
  • Then, weld a mounting plate to the frame’s rear center and bolt the engine to it. Using set screws in the clutch hub, attach a belt to the engine crankshaft. 
  • Correlate the axle sprocket with the clutch sprocket by sliding the Uni-Hub along the axle. 
  • To anchor the brake band, join a bent 3/8-inch rod to the frame so that it traverses in front of the brake drum. 
  • Set bolts on the Uni-Hub, drum, and bearings should be tightened.

The Essential Parts of a Go-Kart

Go kart Frame

  • The frame is made of two types of steel:
    • Round pipe: Although steel pipes on a kart looks cool, it is harder to handle and weld together.
    • Square (angular) steel is less expensive and simpler to bend or join, but it is not as eye-catching.
  • Welding Techniques for Go-Kart Frames
    • The frame can be made by combining pipe and square steels.
    • Weld all of the frame’s pieces together correctly and precisely. Install supports as needed.
    • Check that the welded joints are hard and strong enough to withstand any rough rides.
    • After every test ride, thoroughly check the go-welded kart’s points to ensure that it is formed to last.

Go kart Engine

There are two types of go-kart engine

  • Air-cooled engine

This type is smaller and simpler and will perform better in your go-kart. They also start up quicker in extremely low temperatures because there is no coolant! The disadvantage of air-cooled engines would be that they overheat easily.

  • Water-cooled engine

Water-cooled engines are powerful and can operate indefinitely without risk of overheating. However, the water system of this engine type must be properly configured, or your engine could be destroyed by a simple leak.

Go kart Suspension

The purpose of suspension in go-kart is to make long trips less bumpy. Therefore, shocks are installed in some go-karts. However, because you will not be driving your kart over long distances, you may want to avoid installing any suspension.

Removing suspension will also conserve you a significant amount of money. If you prefer a gentler ride, you can install larger tires instead.

Go kart Steering

The most difficult aspect of configuring your vehicle, after the engine, is the steering. The primary function of steering is to maintain all wheels aligned and not pushed away either towards each other. A well-made steering wheel is essential because it directs your vehicle. Steering requires expert managing, therefore have it constructed by your trusted mechanic. Alternatively, locate and purchase a new steering setup from a major parts store.

 Go kart Tires and wheels

The rear tires on most vehicles are large. Most auto parts distributors sell wide range of wheels that match the 4.10 x 3.50.

Bearings are typically available in 5/8″ and 34″ sizes. Take note that axle bolts in size 5/8″ certainly fit on 1-inch tubing.

Best options:

  • Corrugated tires are more traction and wear resistant than knobby tires.
  • Tubeless tires necessitate tubeless wheels.
  • High-speed rollers are also expensive, but they perform better than low-speed and less expensive standard bearings.

Go kart Brakes

Four Types of Go-Kart Brakes:

  • Scrub brake: When the pedal is pressed, metal paddles are started pressing against both rear tires. This brake can be converted into a hand brake, but it applies a lot of pressure to the tires.
  • Band brakes are simple to repair and relatively inexpensive, but they do not function properly when wet. A band brake stops the wheels by wrapping a metal band on the outside of the brake drum.
  • Instead of controlling movement from the outside, a drum brake expands inside the brake drum to constrain movement. Drum brakes are superior to band brakes since they do not get wet as frequently.
  • Disc brake: The best since it offers superior stopping power, but it is also the most expensive. The drive sprocket can be used in place of the brake disc, but it must be cleaned on a regular basis to function properly.

Go kart Seats

Any seat, old or new, can be used as long as it fits into the kart and protects the riders. The majority will choose the bucket ones made of strong plastic or fiberglass.

Old car seats can also be used, but they will obtain dirt and can be more difficult to wash.

Go kart Seat belts

Seat belts are required safety devices in all vehicles, even small and simple ones.

Seatbelts are classified into two types:

  • 3-point harnesses are less expensive and more commonly used.
  • 5-point racing seat belts (or 4-point racing harnesses) are preferable. Because professional racers no longer use three-year-old racing belts, they are less costly than new versions.

Centrifugal clutch or Torque converter

The centrifugal clutch is a straightforward mechanism that transfers engine power to the drive wheel.

The torque converter is another option that may be more efficient.

In contrast to a clutch, which has a fixed gear ratio, a torque converter has a continuously variable transmission (CVT). Torque converter-equipped karts have differential gear ratios that are remotely activated by a pulley system.

Torque converters extract more engine power basically. It automatically changes to low gear at low speed, producing more torque and power while a lower rotation speed will allow your vehicle to accelerate faster and climb higher.

Rather than purchasing a much more expensive 10 HP engine, you may prefer to evaluate a low-cost torque converter to boost a low-horsepower engine.

Tips when building your go-kart

  • Do not add the extras first, instead of that, complete big parts first, no matter what they are.
  • The unit does include an accelerator, which may be replaced with a basic throttle cable assembly salvaged from a scrapped push mower or a more complex foot controlled gas pedal.
  • Get a go-kart handbook, which will aid you with driving and tuning recommendations.
  • Go-kart requires the usage of a centrifugal clutch, however a drive belt sprocket system and a hand applied or foot actuated gas pedal/clutch can be added as a modification.
  • Certain individuals advise purchasing a set of well-engineered and planned designs that contain some tried and true automotive elements such as Ackermann steering, Castor, King pin inclination, and so on. If you build your kart from proper blueprints, you will be far more inclined to complete it and enjoy it.
  • Use a motorcycle engine with a restriction to prevent you from accelerating as fast as a motorcycle. An engine’s average horsepower is 8 HP, however 10 HP is preferred. With a 10 HP motor, you can generate a greater gear ratio, giving you more torque and allowing your vehicle to continue climbing with less effort.
  • A basic kart can easily cost $600.00 – $700.00 USD, if not higher. A solid set of blueprints may be obtained for roughly $40.00 USD, with some plans costing even less. The plans are somewhat less than $80.00 USD. Unless you’re a pro, this is generally not a horrible idea.

Warning when and after building your go-kart

  • Before traveling on the circuit, make the final test of your go-kart since parts may detach or fail.
  • When driving go-kart, wear protective gear such as helmets and padding.
  • This is not a real automobile and should not be driven on the road under any circumstances!
  • Since this is a plain project with no high-tech engineering or design issues, a high gear ratio or huge engine is not advised for go-kart. Speeds of more than 10-15 mph (16-24 km/h) can cause improperly engineered components to fail.

Conclusion

That all information about how to build a go kart you need to know. We hope you have a good idea for your own go kart

Kart racing is increasingly frequently regarded as a training ground for young racers. Karting gives these rookie drivers firsthand experience with motor racing. They also give training and share experience for motorsport fans who want to one day become professional racers. Many Formula One and NASCAR drivers began their professional racing adventures in kart racing.

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