Gokart Steering

The Gokart steering system involves mechanical steering of wheels on a connecting rod that can be attached to a range of frames to control the steering of a go kart.

• 2 steel tubes with a length of 330mm and cross-section of 25X25mm and thickness of 2mm
• 1 steel tube with a length of 400mm and a cross-section of 50X18mm and thickness of 3mm
• 6 bolts of M6X50mm
• 6 nuts for M6 bolts
• 4 washers
• 1 universal joint of 3/8" for a socket
• 2 individual handlebars
• 1 16X1mm circular aluminum tube of length 1m
• 1 12X1mm circular aluminum tube of length 300mm
• 1 mdf sheet, 3mm thick
• Band saw
• Drill press with 6mm drill bit
• Welder
• 3D printer
• angle grinder or metal file

This step involves cutting the tubes to the right size and shape, welding the steel, and drilling holes in the appropriate locations.

• Cut the 2 steel tubes with cross-section of 25X25mm and thickness of 2mm to 330mm in length
• On one of these tubes, cut out the sides to a depth of 40mm on both ends to create a C bracket (see image)
• Cut the steel tube with a length of 400mm and a cross-section of 50X18mm and thickness of 3mm into four pieces at a 45 degree angle as seen in the diagram
• Weld two of the wide flat steel tubes so that their angled sides meet flush. This will create an L shaped tube. Complete this step twice so that you have 2 L tubes
• Using a drill press and the 6mm drill bit, drill holes in all of the tubes. For the square tubes, this should be at 12.5mm from each end, at the very center of the tube. Drill entirely through the tube.
• Using the same drill bit, drill 2 holes in the L tube at 12.5mm from one side of the tube and 12.5mm from the top and bottom. Ensure this hole goes entirely through the tube.
• Assemble the steel using 4 of the M6 bolts as shown in the image

Note: Do not over tighten the bolts

This step builds the piece that controls the rotation of the connecting shaft.

• Cut mdf sheet to 100mmX40mm
• Drill 6mm holes 76mm apart on the sheet and ensure they are centred
• Place M6 bolt through one hole on the sheet
• Fasten, using liquid nails,the open end of the socket universal joint over the bolt ensuring the bolt is free to rotate, but a fixed connection is made between the joint and the sheet.
• Put the MDF sheet in the centre of the two connecting rods and joint with M6 bolts

Note: Do not over tighten the bolts

This step is to build the steering column and support.

• place the steering frame in location and measure the desired length of the steering column from the universal joint.
• Cut the 16mm aluminium tube to the desired length using a saw.
• place the steering column on the desired angle and measure the height of the column mid way down the column to the frame of the go kart.
• Cut the 12mm aluminium tube to the required length
• Trim the top edge of the tube so that it is cut on an angle to sit flush with the angle of the steering column. This can be done with an angle grinder or a metal file.

Use the attached .STL file to print the handlebar connector and steering column support bracket. If your handlebars have a different diameter hole, you may wish to adjust the handlebar connector to suit your personal handlebars.

If using motor wheels from a hoverboard, you may like to print the wheel mounts as well.

• Slightly sand the connector if the tolerance is too tight for your handlebar
• Use liquid nails to join the handlebars to the connector
• Use liquid nails to joint the column support bracket to your aluminium tube with the angles cut.

This step is for connecting all pieces

• Glue the handlebar connector into the 16mm aluminium pipe
• Glue the other end of the aluminium pipe to the extruded end of the universal joint
• Fasten the support tube to the frame how you desire
• Place steering column into the support tube bracket
• Attach desired wheels to the L brackets of the steering frame