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STEP-BY-STEP INSTRUCTION MANUAL

GO-CART

Designed and Built by Kevin Ayer

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Summary of Contents for GO-Cart

Page 1: ...FamilyFun com FamilyFun STEP BY STEP INSTRUCTION MANUAL GO CART Designed and Built by Kevin Ayer ...

Page 2: ...nch flat washers 6 W inch lock nuts 6 4 or N by 2 inch eye bolts with wood threads inch galvanized pipe fittings 2 flanges and a 3 inch nipple with threaded ends Lubricating oil 2 7 foot long W inch braided ropes Paint and paintbrushes Boat floatation cushion with straps 18 inch bungee cord TOOLS Tape measure Carpenter s square Pencil Eye and hearing protection Dust mask Work gloves Jigsaw Circula...

Page 3: ...oset rod and the 2 by 4 spruce studs as shown BRAKE LEVER STEERING BAR WASTE 20 20 CENTER SUPPORT FRONT AXLE REAR AXLE BRAKE BLOCK 36 25 25 6 FOOT HOLD 14 STEERING COLUMN SUPPORT 6O STEERING COLUMN 21 BRAKE BLOCK 6 REAR AXLE BLOCKS 11 11 10 FRONT AXLE BLOCKS 10 WASTE WASTE ...

Page 4: ... then use the jig saw to cut around the outer curves see Figures A and B To make the brake lever opening in the seat drill 1 inch wide holes through the wood as shown and then use the jigsaw to cut out the wood between the holes A B FamilyFun com FamilyFun Photographs by Kevin Ayer 12 SEAT BACK SEAT SIDE PANEL SIDE PANEL 48 16 3K 24 10O 24 11K 8 1K 3O WASTE BRAKE LEVER OPENING ...

Page 5: ...r as shown in Figure 4 FamilyFun com FamilyFun Drilling Tip Place a wood block underneath the piece you are drilling to prevent blow out splinters and to protect your work surface FIGURE 4 Using the K inch twist bit slowly drill holes 1K inches in from each end of the steering bar posi tioning them at a 90 degree angle to the center hole To help index the angle insert a bolt or drill bit in the ce...

Page 6: ... the edge Then use the Y inch spade bit to drill through the center of each of the 1K inch wide holes this time going all the way through the wood FamilyFun com FamilyFun Go Cart Piece Assembly FIGURE 6 Thread the 3 inch pipe nipple into one of the K inch flanges first applying a few drops of lubricating oil to the threaded ends and then insert the nipple through the countersunk hole in the center...

Page 7: ...nt axle flip the axle over and attach the flange again using four 1N inch pan head screws FIGURE 8 Next thread the free end of the nipple into the first flange turning the axle to tighten the con nection until there is about C af inch between the center support and the front axle and the pieces pivot freely Photographs by Kevin Ayer Photograph by Peter N Fox FIGURE 7 FIGURE 8 FRONT AXLE CENTER SUP...

Page 8: ... center support does They should also extend N inch over the ends of the axles where the wheels will go Note Overhanging these pieces will help to better support the seat back and the wheels when you attach them later FamilyFun com FamilyFun FIGURE 10 Attach the front axle blocks next overhanging them N inch past the wheel ends of the axle but keeping them flush with the long edges Note while one ...

Page 9: ...een the head of the bolt and the collar Insert the bolt through the K inch hole on the smaller face of an angle bracket as shown Slide a K inch washer onto the bolt and insert the bolt through the center of the wheel Slide on a W inch washer then screw on a W inch lock nut tightening it untiltheassemblyissnugbutthewheelstillspinsfreely FIGURE 12 A B Use four 1N inch pan head screws to attach the w...

Page 10: ... it on the mark Use two 2K inch drywall screws to secure the two pieces together FIGURE 14 A FIGURE 14 B FIGURE 13 FIGURE 14 A B Using eight 1X inch drywall screws attach the steering column side panels lining the edges up with the top of the steering column and the side of the steering column support as shown Photographs by Kevin Ayer 9 STEERING COLUMN STEERING COLUMN SUPPORT ...

Page 11: ...crew it to the axle blocks and the center support Position the steering column assembly on top of the center support butting it up against the seat Fasten it in place by screwing through the plywood into the center support on both sides FIGURE 16 Attach the steering bar to the top of the steering col umn with a W by 3K inch bolt sandwiching W inch washers between all pieces Thread a W inch lock nu...

Page 12: ...go cart Butt the brake blocks up against the rear axle and use 1X inch drywall screws to fasten them in place screwing down through the seat top Make sure the brake lever is centered in the hole so that it can operate freely FIGURE 18 Turn the go cart on its side and using three 2K inch drywall screws attach the footrest to the underside of the centersupport about 5 inches back from and paral lel ...

Page 13: ...ame side of the steering column and the front axle Do the same with the second length of rope on the opposite side of the steering assembly Now make sure the front axle and steering bar are parallel Pull each rope taut and knot it around the axle eyebolt Trimtheropeends leavingalittleexcesssoyou can retie them if they loosen Now you re ready to roll 12 FamilyFun com FamilyFun Photograph by Mark Ma...

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