[Che]

Hi guys. I'm starting up this thread as I have a summertime project on my mind - to build an offroad go-kart/buggy with my 10yo nephew. I've investigated buying a new kart/buggy, but none are ideal, and the ones I really like are super expensive. My budget isn't really worked out yet, but I don't want to be spending much more than $2K. So far I know a 9hp (270cc) Honda industrial motor will cost $800-ish (new), MIG welder hire is $120 a day, and that's where i'm at right now. Got lots to learn and lots to figure out - I hope with the help of you guys I will end up with a beaut toy that'll see out a few years of abuse. Any advice or suggestions along the way would be much appreicated.


Starting with the basic design - I think something along these lines will be most practical:






I guess the world is my oyster in terms of design cues. I think one of the first things I need to figure out is a suspension design - whether I should just use big rubber to absorb the blows or if I should opt for some kind of wishbone setup. I don't want to get too tricky, but at the same time I don't want a kart that's no fun to drive because I took the easy build option.

So lets start with costs. I guess i'll be needing a torque converter/CVT to suit, four wheels, a disc brake system, a seat, steering wheel and god knows what else. Anyone care to kick things off for me? Any info is much appreciated.

[sideways]

Assuming you're buying all new stuff.

You can get a Chinese torque converter/cvt for $150-200. Comet closed down so you can't get genuine ones any more. Wheels and tyres, if you want quad wheels and tyres then figure $200 a corner. Disc brake system, probably $50 off eBay. Seat depends on what style you want, if you want a roll cage you'l need a harness to go with it. Axle complete with hubs and bearings will be a few hundred, IIRC the bare Edge ones are $250 and are 4130 chromo. There used to be a guy selling slider kart axles on gumtree complete with sprocket, hubs, discs and bearings for $200. Use some mini pattern trailer hubs with trailer spindles for the front, dunno how much that will cost. Factor in a hundred for steel. You can probably just get away with buying the tube and scrounging all the other bits you need.

Then there's all sorts of little things like tie rod ends, cables, steering bushings ect.

Buy a cheap arc welder or gasless mig or you'l end up spending your whole budget on just the welder hire.

[Che]

So I went and had a go of the Chinese slider karts... it's was kinda along the lines of what I expected. Rough welding, already rusting upon import, the paintwork doesn't seem to be primed, a bit cramped for a 6'2" guy, and not very fast with a 100kg lard arse in the seat - it's be even slower in soft sand. That said - it was still good fun! With bigger wheels, a 12hp motor and sorted gearing it might make for a more lively experience.

But, I just think something more along the lines of the purple rig in the above post will make for a better starting point. Time to get the thinking cap on.

[sideways]

You can get sliders with the roll cage like that trax 2. They're pretty flimsy looking though.

Fwiw the trax 2 is nothing but a Fun Kart 3 with a roll cage. The base is exactly the same. You can borrow my Fun Kart 3 plans and design your own roll cage if you want. It'd be easy as to design one from scratch but at least with the plans you don't have to measure up a ton of random stuff, you know it's going to be ergonomically sound.

The guys at Edge are super friendly. If you rock up there they might have a trax or funkart you can have a go on, there's never been one there when I've been though.

[Che]

I'm going there tomorrow morning. The guy said there's one in stock but it's getting sent out about midday.

[bakerboy]

The blue one is decent, although slow, and lack of suspension is a bit of a let down. The seat is pretty rough though haha

[missmyljdaze]

How about something like the fun kart3, with a roll cage added- based on Hayden's plans, and bolt on one of the chinese motorcycle engines [loncin 200cc]
There was a brand new one of these engines, [electric start, 4 forward & 1 reverse gear- but minus some electrical stuff] on the Edge Buggy Forum going for $250.
No idea what they are like, but I think they are honda clones.

Using a bike engine like this you can fiddle with the sprockets for appropriate gearing.
------------------------

Any luck chasing up the bloke in greenwood that was offloading his kart?
That would save a lot of mucking around- but still give you both some stuff to do- tear down, clean up and repaint, replace front tyres, spruce up the engine, clean out fuel system etc.

stephen

[31zook]

R1 motor, disk brakes, big enough tyres for sand, build the rest

[Che]

31zook wrote:

R1 motor, disk brakes, big enough tyres for sand, build the rest

Lol! Damn straight! A day into gathering info and i'm thinking it might be best to buy an el-cheapo kart for my nephew, while I put together something more 'adults only' for myself

[31zook]

Even if you just built one cool cart and then put some sort of idiot proof system in it so anyone can have a go...

[sideways]

Turbo 'busa powered Barracuda or hand in your man card!

Buy this, it's an ex hire kart. Built super tough. GX160 and the wet clutch are worth that alone. Pull the street wheels/tyres off, sell them and get some decent offroad tyres. Replace the belt with a chain, fix the brakes and you've got a kart that will never die.

http://www.gumtree.com.au/s-ad/middle-s ... 1027779962

[Che]

OK, change of plans. Looks like a Chinese slider kart is the best option. I just went to Edge Karts with my nephew - they had a Fun Kart III there - he's got a lot of growing to do before something of that size is going to suit him. Seeing this plan is more about putting a smile on his face than putting one on mine I don't think a kart for grown ups is going to work. Bummer.

I think my plan of buying a cheapo kart and building a more serious toy on the side is the best bet.

[alien]

Che, why dont you equip your sierra build towards this idea? so you can use the sierra as your weapon on the tracks???

[Che]

That's not such a silly idea. I've got to get my front end suspension sorted in the coming months (the ARB bar has dropped the front leaf springs too much) - maybe I could shoot for a rally spec Sierra? Lowered instead of lifted? That'd be a first!

I certainly prefer burning up beaches and fire trails more than technical driving (even though most prefer the other way around) so it kinda makes sense... Hmmm... good idea Aron. I'll ponder that for a while.

[Jezza86]

firstthing i think of when someone says suzuki rally car
escudo
http://www.youtube.com/watch?v=VafUiWtjH-Q

[Zook_Fan]

If you're going to go the buggy way here is the forum for inspiration: http://www.minibuggy.net/

[alien]

when i think of a fast sierra i think "Raid De Himalaya"



Solid, reliably built rigs that take some crazy abuse =)

[bigrig91]

Just buy a new polaris rzr 1000. Spare 28k. You can pick up a rzr 900 with low hours for around 16k.

[greenzook89]

alien wrote:

when i think of a fast sierra i think "Raid De Himalaya"
Solid, reliably built rigs that take some crazy abuse =)

Thats awesome, especially the supercharged ones!

[Marko_SJ]

bigrig91 wrote:

Just buy a new polaris rzr 1000. Spare 28k. You can pick up a rzr 900 with low hours for around 16k.

That is around 15k more than a cheap sierra.

[bakerboy]

not in wa it's not haha

[Marko_SJ]

bakerboy wrote:

not in wa it's not haha

Watch some videos of RZR's

[tassie jeeper]

here is the buggy me and my father built we bought the dirt devil kart drawings from the internet and used it for a base line and modified it to suit our needs we used a 230cc 5speed thumpster engine it has disc brakes front and rear and rack and pinion steering. total cost is about $2K

[Jase69er]

I'm building a Dirt Devil too for my young fella. Awesome little buggy. Gunnar run a Briggs & Stration Animal 206.

[tassie jeeper]

Jase69er wrote:

I'm building a Dirt Devil too for my young fella. Awesome little buggy. Gunnar run a Briggs & Stration Animal 206.

using a torque converter?

[Jase69er]

No, 16 pinion, 100 main.

[tassie jeeper]

Jase69er wrote:

No, 16 pinion, 100 main.

ok cool