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How to Make a Go Kart Body

Driving go-karts is an enjoyable experience for adults and children alike. Although previously used go-karts are easy to find, offer a proven history and are often inexpensive, building a go-kart from the ground up is a rewarding experience the entire family can participate in together. It is important to follow plans and directions, exercise proper safety precautions and take special care when constructing the body of the kart, since this is what will protect the driver in the event of a crash.

Things You'll Need

Tape measure
Craft paper
Scissors
3/8-inch thick plywood
Jigsaw
2-by-4-inch boards
Drill
Screws
Quick-set drywall compound
Orbital sander
Primer
Fiberglass matting cloth
Cloth marker
Measuring tape
Calculator
Car buffing wax
Liquid resin
Activator
Paintbrushes
Screwdriver
Fine sandpaper
Paint

Instructions

- 1
  Measure the dimensions of the go-kart frame. Transfer these onto craft paper with a pencil and connect the outline to give you a rough stencil of the go-kart body size. Cut out the stencils.
- 2
  Fit the paper against the kart frame to check for proper dimensions and place the stencils on plywood.Trace the outlines on plywood and cut out with a jigsaw.
- 3
  Create a mold by attaching the plywood pieces with screws and 2-by-4-inch beams. The open end of the mold should be at a slight angle compared with the top so the body mold can be pried out after it hardens. The entire mold should resemble a bathtub..
- 4
  Fill any gaps in the mold with quick-set drywall compound. Wait two hours for the compound to dry before sanding the mold to round any sharp corners and smooth irregularities in the wood or drywall compound to prevent bubbles and ripples from forming in the go-kart body. Apply a primer over the inside of the mold so no drywall compound is transferred to the kart body while it sets.
- 5
  Purchase 1/16-inch thick fiberglass matting cloth from an auto parts store. Measure the interior walls of the mold before you determine how much matting you need to buy. Double the measurements because the body will need to be 1/8-inch thick, or two plies of cloth. Trace the paper stencils made in Step 1 onto the matting and cut out.
- 6
  Multiply the interior surface area of the mold by 0.188 and divide by 0.231 to determine how many gallons of resin are needed to mix with the matting. Follow resin package instructions to add the appropriate amount of activator and mix.
- 7
  Coat the inside of the go-kart body mold in car buffing wax. Apply activated resin to the matting cloth and shape into the mold. Allow it to dry for 24 hours.
- 8
  Cut any excess body that extends beyond the mold using a jigsaw at slow speed. Pry the body out of the mold with screwdrivers. Examine the mold and use fine sandpaper to wet-sand any defects in the fiberglass surface.
- 9
  Apply auto body primer and paint to the fiberglass body before installing over the go-kart frame.

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