Dually Go Kart
DIY Go Kart with a punch
Overview
Summer 2024
Individual project
Skills
Wood Working
Tig Welding
Metal Working
Basic Engineering
Keywords
Fun
EV
Steering Mechanism
Dually
Design Story
I don't know about you but I loved my power wheels when I was tiny enough to fit in one. As a teenage boy, I loved to go on go-kart circuits or go off-roading on 4-wheelers.
This project was a perfect project to re-ignite my passion for small and fun motorized vehicles and learn and apply my fabrication skills.
Every boy's childhood
I used to have a green power wheels I loved to ride in my front yard but one day we lost a charger and never got a new one. Sometimes I still get sad thinking about that poor young boy.
This project is for me and the young boy I used to be.
Preperation
Sketch and build a scale model of the kart before building a full scale model. This step can help with verifying the viability of the design.
Febrication
Build the essential components of the go-kart, such as the drivetrain, steering rack, frame and more.
Lathe Machining
Tig Welding
Fabricated Metal Parts
Welded Metal Parts
Single beam construction is enough for structural integrity and helps to reduce the overall weight.
Design
What is good in go-kart if it does not look cool? Here are body panel design options I have explored.
Last minute, I decided to make it a dually, with two tires on each side, helping with traction, better braking performance, and fail-safe for flat tire, which did happen but thanks to the second tire, I didn't notice it till I got off and checked in person.
Then I crafted the body using cardboard. lightweight and easy to handle, it is the perfect material for the body of go-kart.
Dually modification
Plywood panels are added for structural strength and to act as a platform for different components including seat, brake and gas padels.
Failed attempts
1. Failed attempt to make a drum brake using sheet metal and rubber pads.
A steering wheel and backrest is added.
Change of plan for rear wheel from single wheel to two on each side.
This will not be the last time adding wheels.
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2. Failed attempt to make a drivetrain chain tensioner.
3. The brake system built with spring and hinge was too weak for the weight of the kart and end up getting twisted.
The inside of the tensioner is lined with a metal sheet to reduce the ware from drive chain rubbing aginst it.
