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DIY Diesel Go Kart

A go kart is a great way to introduce a child to driving. It̵7;s also a great way to spend a day with your child building a creative project. You can create your own go kart with a diesel engine, brakes and custom-placed foot pedals. The project only takes about a day once you have all of your supplies and tools assembled. Look over the whole project from start to finish before you begin so you̵7;ll be able to anticipate problems you need to solve.

Things You'll Need

Steel tubing
Tubing bender
Welder
Steering blocks (2)
Steering rod
Spindle brackets (2)
Wheel hubs (4)
Wheel rims (4)
Tires (4)
Rear axle
Sprocket
Brake hub
Bearing cassettes
Diesel engine
Mounting plate
Clutch
Chain
Foot pedals
Brake cable
Throttle cable
Plywood
Saw
Foam rubber
Vinyl
Stapler

Instructions

- 1
  Build the chassis by welding 1-inch steel tubing together. Cut the tubes with a hacksaw and lay out all the frame parts so that you can see how they go together. Bend the tubes to make them fit each other. Weld the frame together and test it for strength by pressing with your foot. Also visually inspect the welds to make sure they are solid.
- 2
  Weld an upper and lower steering block to the steering post. The steering post is part of the frame you have welded. The steering blocks guide the steering shaft. Thread a steering shaft through the steering blocks. Bolt the steering shaft to a steering rod. This rod runs perpendicular to the shaft and will connect to the wheels. Attach the steering rod to spindle brackets on both sides of the frame, and thread the spindle brackets into the wheel hubs. Mount the tires on rims and bolt the rims to the hubs.
- 3
  Push the rear axle through a sprocket. This sprocket will attach to a chain from the motor and turn the axle. Slide a brake hub over the axle. Slide two bearing cassettes over the axle and attach them to the frame with brackets. Attach the ends of the axle to wheel hubs. Mount the rear tires on rims and attach the rims to the hubs.
- 4
  Mount the diesel engine. Weld a mounting plate to the frame and bolt the engine to it. Slide a clutch over the engine̵7;s crankshaft and tighten the set screws to hold the clutch in place. Slide the axle sprocket along the rear axle so that it aligns with the sprocket on the clutch. Run the chain around both sprockets. Remove links or add links until you have about 1/2 inch of slack.
- 5
  Bolt left and right foot pedals on either side of the steering column. These should be mounted to the frame where the driver can reach them. Attach brake and throttle cables. Attach the brake cable to the left pedal and the throttle cable to the right pedal. Run the cables to the rear of the vehicle. Use a cotter pin to attach the brake pedal to the brake drum. Attach the throttle cable to the engine throttle.
- 6
  Cut a square out of plywood. Make it about 18 inches by 18 inches. Staple foam rubber padding to it. Cover that with vinyl, which you can also staple. Bolt the seat to the frame.

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