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| Scratch-built Go-Kart |
The 60's
I’ve always been interested in mechanical devices. I guess it was inevitable since my dad and two grandfathers were mechanically inclined. My mom’s father was the chief mechanic for one of the large corporations based in my hometown. He found this scratch-built go-kart for his three oldest grandsons. It was sometime in the 60s. The kart was built using round tubing and sported a Clinton, 2 cycle, 2 horsepower engine. Those 2 cycle engines were fast. At some point the original engine was replaced with what I only remember as a larger blue engine I believe to be a 4 cycle Briggs & Stratton, but I’m really foggy on that one.
70's and 80's
Sometime in the early 70s I took my first ride in it behind my grandfather’s shop in Hanover Township, PA. By this time the gas pedal no longer worked and a string was tied directly to the linkage on that blue engine to control the throttle. This configuration made driving the kart especially difficult for such a young boy, but I still loved it.
A few years later my cousins gave the kart to me. By this time it was 1977 and I was nine years old. My grandfather tried to get it running, but the old engine didn’t have any life left in it. Sadly my grandfather and I were never able to get it running again because he passed away the following year.
My dad was able to get a used horizontal shaft Briggs & Stratton, 4 cycle, 3 horsepower engine from a friend (Model Number 80202-0016-01). The first time we messed with it I was shocked by the spark plug. Wow that hurt. Unfortunately both the bolt hole pattern and the crankshaft size were different than the previous engine. So, we had to drill new holes and find a centrifugal clutch to fit the replacement engine. Since the gas pedal was not working for many years, it had rusted to the frame and would no longer move. Temporarily we took a throttle cable and placed it on the steering support with a Tee handle and I was finally off and running.
I drove it for a while with the Tee handle throttle setup but it became a pain. I mean a literal pain. The casing or conduit the cable ran through was made of tiny wires encased in plastic. When slowing the engine down I tended to get jabbed with these tiny wires. So, I embarked on my first real solo engineering project. Get the darn gas pedal working. Soon, I had a real gas pedal.
Now it was time to paint. It took several days to remove the rust and the peeling paint. Dad gave me some old grey metal paint that I used to paint the bulk of the frame. I accented it with black on some of the support members and the wheels. Eventually I painted the wheels with that fake chrome color that always dulled after exposure to the sun.
The tires were in terrible shape. Another cousin had a kart that was lost in a tornado so he gave me some used tires he had hanging around his dad’s garage. They were better than what I had, but still weren’t so good. We did finally buy 1 new tire. Looking back, I can’t understand why we didn’t buy four new tires. They weren’t very expensive.
I drove that kart all over the place for many years. Eventually, the throttle cable broke while some neighbor kids were playing with it. So it sat in my grandmother’s garage for nearly twenty years. I made sure there was plenty of oil on top of the piston and I’d occasionally start it just to make sure the engine didn’t seize.
Summer 2007
The fall of 2006 my nephew, my sister-in-law's youngest son, spotted the kart in the garage. He was born to drive. His older brother had a John Deere Gator he received as a birthday gift one year. Little Tony was driving that Gator before he could walk. Now every time he or his brother visit they want to see the kart. Since then I had moved it down to the barn to free up some much needed space in the garage.
Last Thursday, the first day of summer, June 21, 2007, I finally bought a new cable. When I got home I went down to the barn, strapped the kart to the back of my garden tractor and towed it up the hill to the garage. It barely made it, that darn kart is heavy and it was causing the tractor to loose traction on the hill. Anyway, the new cable wouldn't fit so I began to make some new brackets and re-engineer the pedal. I also wanted to add a means of limiting the speed since my nephews are still pretty young and I don’t want them to get hurt when they finally get to drive it.
First start in many years
Meanwhile, it had been several years since the engine was last started and as luck would have it I forgot to empty the gas tank after the last time I ran it. I think it had been about two years, so the old gas had turned to varnish and gunked up the carburetor.
The next night I began to tear apart and clean the carburetor. I reassembled it that Saturday and she started right up. Subsequent starts over the next several days only require a single pull on the starter before she would fire up. They don’t build them like that anymore. The only problem was the jet would no long properly adjust the air fuel mixture. At some point I'll need to replace it.
I decided to run the model number from the engine just to see what parts were still available. Much to my surprise, it turns out the engine was built in 1969. I thought it was newer than that. I like old things.
Bigger isn't always better.
On Monday night I got back to work on the pedal. I spent more than two hours reconfiguring it with the new brackets only to find out the new cable binds. You know how everyone always says bigger is better. Well, not in this case. The new cable is a heavy gauge wire with a metal conduit while the old one was thinner with a plastic conduit. The new one can't make the 180-degree turn that's required without binding. So, it's back to the drawing board unless I can find a thinner cable with the plastic conduit.
Tuesday after work I stopped at several auto parts stores looking for the another cable. I even called several lawn mower and tractor places, but none of them had cables in the length I needed. I needed about 85 inches because the carburetor is oriented such that it faces the rear of the kart. I did, however, find a store that carried an extra long choke cable. This inspired me to grab a choke cable I had laying around the barn to experiment with. This cable wasn't long enough to reach the pedal, but it could prove that such a cable would work. After a round of boccie (yes we finally won one game) I went down to the barn, got the cable, sprayed it down with some WD-40 and hocked it up.
As usual, the old B&S started on the first pull. What an engine. I grabbed the choke cable and forced it into a much tighter radius than need and proceeded to test it for binding. No matter how tight I got that radius she still worked!
This is a relief. If the one lawn mower shop can't produce the proper cable today than I'll just buy that extra long choke cable and cut off the end I don't need. I hope to finish it soon so the boys can play with it by this weekend or during the 4th. That is, after Uncle Larry takes a spin or two!!! Maybe this winter I'll take the time to repaint it.
Continuing saga of the gas pedal.
Well, the lawn mower shop wasn’t able to find the type of cable I needed. However, Lowes replied to an email I sent with some web site suggestions. The first one only sold the braided cables, but the second site (http://www.psep.biz/store/universal_mower_cables.htm) does sell the solid core cable. However, it turns out that the choke cable from the parts store is a little cheaper and I wouldn’t have to wait for it to be shipped.
So, I stopped after work and bought the choke cable. I brought it home and cut off the end I didn’t need. I then made a mounting bracket able to accept a swivel connector and attached it to the pedal. I re-mounted the pedal and then sized the cable with a little extra slack in case either end ever breaks. It works. I’m not really that happy with the way the spring is mounted but for now at least it can be driven.
Next I’ll need to change the oil and tune her up a little. After that, it’s to the races . . .
Addition of kill switch
Well, July 5th brought nothing but rain, so I took the opportunity to connect a much needed kill switch. The kart never had one before. It was usually shut off by grounding the spark plug with a screw driver or flooding it by fully engaging the choke. So, Dad had several toggle switches from some old control panel. I took one and wired it up the to engine. This model Briggs engine has a wire attached to a non-conductive mounting block on the outside of the cylinder head. If you attach a ground to it, the magneto shorts out thus shutting down the engine. Once I tested it, I quickly made a small metal dashboard and mounted the kill switch to it. I drilled a small hole in the frame section supporting the steering and snaked the wires through it then down along the inside of the main frame rail along the seat. Once past the seat a set of wire ties hold the wires so they do not drag along the ground. Finally, the wires snake their way past the fuel tank and up to the mounting block.
After completing the kill switch and dashboard fabrication, I decided it was time to touch up the paint on the fuel tank and pull start. I had finally found some paint that is close to the original engine color. Now it looks a little better. I also ordered new stickers but in the mean time misplaced them somewhere in the house. I then painted the dashboard a nice silver color. Once dry I reassembled the engine parts and dashboard then took her for a spin. Unfortunately a couple of old problems resurfaced. The chain came off the wheel sprocket and some gas splashed out of the tank which in turn eat away the new paint I just put on the tank.
I’m wondering if there is any painting technique or type of paint that would eliminate the gas problem. As for the chain, it seems that the problem is when the drive wheel moves to much, usually as a result of a sharp right turn. I might be able to solve the problem with a new wheel since the existing one appears bent and wobbles a little. However, the problem doesn’t occur enough to warrant that right now.
First Real Run in Years
We packed the old Kart up in the GMC and took it to our local church parking lot. My nieces and nephews drove it many times around the lot. It was really hot out that day and the engine got very warm but she took all the kids could give her. They, as well as I, had a blast.
Future Plans
As I mentioned above, I'd like to repaint it this winter. I probably will not keep the current color scheme. It is a little drab. I want something eye-catching.
It would also be nice to add a few body panels to the kart. This would be a great opportunity to experiment with custom-made fiberglass panels. I think it would look nice if I could mimic either an Indy car or an old Bugatti Type 35C Grand Prix Racer.
I’m also considering replacing the axle, something I’ve always wanted to do. Currently the kart has a dead axle, which is great for paved tracks but not dirt. There really isn’t any local paved area to ride and it is illegal to use the streets or side walks. We do have access to several nice dirt or gravel lots so a live axle would really pay off. Unfortunately, this would require a lot of re-engineering due to the way the existing axle is welded into place.
Spring 2008
Well, my wife got pregnant with our first child later summer 2007 so I was not able to repaint the kart like I had planned. However, we've taken the kart out several times and rode it on the back patio and at a local parking lot. It does very well for such an oldie. Still need to find some tires but the existing tires are so old I can't seem to be able to decipher what size they are.
Fall 2008
Took the kart back out to the parking lot so all the kids could ride it. My oldest nephew got on first and took off towards the right corner of the lot when the chain jumped off. I always had trouble with that darn chain. It took a few minutes, but we got the chain back on and he took off again. This time he only got a few feet away when it just wouldn't go anymore. The engine was running and the chain was still on, but she just wouldn't move. I walked up to him and pulled the kart backwards. It rolled fine, what's going on? Then I tried to push it forwards but it wouldn't go. The right front wheel bearing was gone.
The Search for a New Wheel Bearing
I looked long and hard but could not find a replacement wheel bearing for the now 50+ year old wheel. So, I found a site that had some wheels close in appearance to the ones on the front of the kart. I ordered a pair and got them a few weeks later. I had to fabricate a spacer so they would fit properly but they seem to work. However, it was late fall by now and it was time to put the kart back in the barn for another winter.
Spring 2009
The boys came over and wanted to see the kart again. So, I took them down to the barn and we attempted to start it. This time, no luck. The carb finally needs rebuilt and now would be the right time to get a new jet as well. Only problem. My son is now 1 and running around like there is no tomorrow. Most of my time is spent making sure he doesn't get hurt. He loves the outdoors so I doubt if I'll have time to work on the kart this year. Besides, it might be best to wait till next year so the nephews will be a little older and more capable of riding the kart without hurting themselves.
Spring 2010
Well, another year has gone by and the boys are getting bigger. Their friends have much newer karts and they just want to be able to ride. As it turns out their friends were selling their karts so they could buy a couple of bigger, newer, faster ones. One kart was really nice, but still was only a single wheel drive. The other was a live axle but pretty beat up. So, we offered them $140 bucks but they wouldn't go for it. I guess I now really need to rebuild that carb and get my old one kart back on the road. I'm looking at buy a set of rear wheels for it to go along with the set of front wheels I bought on 2008. I found a complete wheel, hub, sprocket, and tire assemble for $40 each. Might be the way to go seeing as the old assembly is seized up. I've got to do some further investigation first. Check back soon.
Summer 2010
Antonio helped me push the Kart up the hill with Lorenzo driving. That was interesting. It was about 90 degrees and we were worn out by the time we got up the hill because all 4 tires were flat. We washed the kart and checked for a spark. Then attempted to start it. No luck, I still need a carb kit. I tried getting the kit from the Briggs site but it no longer recognizes my engine model. What a shame. So, I tried a local repair shop and they said Briggs no longer makes the repair kits for engines as old as mine. They think they may be able to get an aftermarket kit but suggested I tear it down and inspect it first. I guess I know what I'll be doing this weekend. Heck if things go well maybe I'll do something about the paint on the gas tank too.
Well, that weekend came and went and I still didn't get time to work on the old kart. August finally arrived and the entire family was in for a visit at my sister-in-laws. The little guy was supposed to be taking a nap so I pulled the carb off and cleaned it yet again. I tried starting it but no luck. It just sputtered once and that was it. I pulled the plug again to make sure I was getting a spark and I was. I decided to spray the plug with choke and carb cleaner and reinstall it. Still nothing. Oh well.
A couple of hours later I return after doing some yard work. I pulled to starter once and to my surprise she came alive again. This engine is amazing. 42 years old and still running with all of the original parts. It is in bad need of a carb kit, which I can't find, but it runs. Now to load it up and take it to my in-law's house where the family is gathering.
Here are some of my nephews posing for the camera just before the oldest, Mario, takes off on the second run of the season. This is the first time they've been allowed to run it in their neighborhood instead of a parking lot. I'm not sure if they can legally ride it on the side walks, but I know they are not allowed to ride it on the road.
Soon after, the little guy and Angelina were chasing after Mario in the go-kart so he could take them for a ride. All of the kids drove the go-kart the rest of the evening and were so exited the next day when we took it out again. The chain keeps popping off so at some point I need to tighten it up or maybe even replace it. I can't remember if it is the chain that used to be on the original engine or if we replaced it back in the 70s but it is at least 30 years old.
Created on 06/26/2007 08:47 AM by admin
Updated on 09/17/2010 06:20 AM by admin
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