Go Kart

Ever wanted to make your own go kart? Well it looks like you're in luck!

Behold the Lightning McQueen push powered go kart with functioning turning and a track distance of 200m from a 10m push.

This is a fun way to train your welding skills as well as your understanding of steering systems and mechanics, as well as working on a semi-large project. I made this go kart as part of a school engineering competition, in which we had to design and create our own karts from scratch.

Material:

1. Using these measurements in the orthographic, acquire steel box section of 22x22mm.
2. Cloth
3. Paint supplies
4. M8 bolts
5. M8 nylock nuts
6. M10 bolt + wing nut
7. 4mm rivets
8. Zip ties
9. 520 x 110mm MDF

Tools/Machines:

1. Chopsaw
2. Metal file
3. Hacksaw
4. Scriber
5. Centre punch
6. Hammer
7. Pillar drill
8. Engineer's square
9. Sliding bevel/Cam gauge
10. MIG Welding gun/spool/gas tank
11. Hand drill
12. Rivet gun
13. Tape measure/Ruler
14. Scissors

Safety Equipment:

1. Goggles - most activities
2. Apron - all activities
3. Welding jacket - when welding
4. Welding gloves - when welding
5. Welding mask - when welding
6. Helmet - when testing

Using either a ruler or tape measure, measure out the lengths specified in the orthographic. Use an engineer's square or sliding bevel gauge for either 90 degree cuts or angles, and mark out using a scriber.

*TIP* - Always measure 2mm more material than you need! It's better to go over and have to cut down than remake a part.

Cut measured box section using either a chopsaw or a hacksaw, whichever is available. Make sure you cut slowly with the chopsaw to not damage teeth, and ensure lubricant is flowing. After cutting, use the metal files to clear off and smooth the ends to remove excess.

Use scriber to mark out locations of holes for front and rear wheels. Use a centre punch and hammer so that the drill bit does not slide. Use a pillar drill to first make a pilot hole using a 3-4mm bit and then drill a larger hole to the thread size of the axles. The higher up the holes, the lower to the ground the kart will be.

*TIP* - If available to you, use oil to reduce friction and give a better finish.

Welding steps:

1. Wear appropriate PPE (specified earlier)
2. Turn on power
3. Turn on extraction
4. Align workpiece using magnets
5. Turn on gas for welding
6. Turn on welding gun
7. Earth welding gun using clip
8. Enjoy!

*TIP* - Tap weld large frames first to prevent deformation, and weld slowly in small circular motions.

Use M8 nuts and bolts to assemble parallel linkage mechanism and bolt in wheels. Use washers to decrease friction from linkage. Weld tube to turning bar and join to linkage using the large M10 wing nut and bolt.

Use rivet gun and rivets to attach the chair to the base, and a footrest near the front.

The car should look similar to the photo above before adding designs. If you wish to stop here, I hope you had fun and go try out your kart!

Otherwise, measure out the sections of cloth you wish to add and decorate it using paints for your chosen design. When satisfied, cut small holes on the edges using scissors and use zip ties to attach to the frame. You can also use the MDF as a number plate, by drilling holes on the rear bar and using the rivet gun.

What are you still reading for! - Go out and have fun with your new go kart, and I hope you enjoyed this instructable.