Chapter 20: Some (Re)assembly Required

Posted: April 18, 2010 in bugatti go kart, building a go kart, go kart body, go kart pedaling, go kart steering
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To have reached this point has been pretty gratifying. Now that we have the paint all on, the number in place, I felt we could start putting it all back together. The front wheels went on quite easily and we also put our louvers back on. We also finally removed the last of the blue painters tape from the steering column and put the steering wheel all back in place. Now we’re cookin’ with gas as one might say.

Cutting off the end of our exhaust pipe.

Before I put the exhaust back into place I went ahead and trimmed the end that mounts into the engine compartment. If you remember back in “Chapter 13: Does an engine without an exhaust still make a noise?”, we ended up with the exhaust pipe hitting our crank pedal.
Before we had removed it I marked the spot where it would need to be trimmed with a Sharpie so all we had to do here simply was cut it. I went ahead and held it in place in a miter box (which worked surprisingly well) and cut it on the line we had drawn.

Because our exhaust is nothing but a kitchen drain pipe made of chrome plated brass it cut pretty easily. I wasn’t terribly concerned with it being a perfectly straight cut since it will be on the inside of the kart and not visible, but I tried best I could. Once the cut was through I then was sure to sand the now razor sharp edge to dull it up. Last thing I needed to do was have one of the boys slice their leg open while pedaling down the road. My wife would kill me. Once we were all done with this step it was just a matter of screwing it back onto the side of the body.

Our drive wheel mounted, showing the block that the wheel mounts to.

Onto the rear wheels. I’ve been thinking a bit about the mounting of the rear wheels. I think I’m going to go ahead and rebuild some new mounting blocks. I never had painted the original ones we had created and after putting the wheels back on I just don’t feel that they’d be strong enough or at least last very long so I don’t want to go to the effort of painting them only to have them break soon thereafter.
The alignment of blocks is also bit off, but more than that is the sheer strength. What I’ll do is rather than build a mounting block out of 1×6 as we had before, I’ll pick up a piece of 4×4 and cut it in a wedge shape to align the wheels straight, while also mounting flush to the frame. Am I really looking to rebuild these mounts to insure they’re strong enough, or am I not wanting to finish this project? Good question. I’m not sure I can answer that but probably both.

With the rear wheels now mounted, albeit temporarily, we have a rolling kart again. The kids are really excited to see it all back together. I went ahead and pulled it off the stand to get some shots when one of the boys enthusiastically asked if he could take a ride. Sure, why not. I said “It’s not ready to pedal, but I could push you around a bit.” He sat in it and wrapped his hands around the wheel and just grinned ear to ear.

All rev'd up and ready to roll.

He turned the wheel back and forth a bit and off we went down the street. It really was fun to see. I pushed him down the sidewalk and told him to go ahead and turn up the neighbor’s driveway where we would turn around and head back home. I thought I may have even heard him making some engine noises, but then I quickly realized what I heard in fact was the spokes on the front wheels scraping against the lower control arms. Ahh! Abort! Abort!

We limped ‘er back to the garage and I realized that in the haste to get some pictures of it all back together I neglected to put the spacer on the front wheels that moved them towards the outside to clear the arms. I removed the wheels, put our spacers into place, and put it them back on. And also took a mental note to not to make that mistake again.

You can see where our spokes grazed our control arm.

On closer inspection I think I can repair it aesthetically, but I’m worried that a crack may have been introduced. Even if there is I think that the strength of the upper will be strong enough to support it, but I’ll just keep my eye on it. Luckily I can remove it and replace it relatively easily from the bottom of the kart. Yet another loose end that could have me working on this a bit longer.

All in all we’re looking pretty good. The louvers, the grill, the steering wheel, the exhaust, each add that bit of detail to make this a pretty cool vintage go kart. In addition to resolving our rear wheel mounts and this new wonderfulness with the front wheel I’m looking to get a seat of some sort added. Oh, and maybe some headlights. I did a bit of looking around hoping to find a discarded bar stool with a back that I could take the upholstery off of. I thought a seat like that would be perfect but no such luck finding one (still glancing at the occasional yard sale though). As a last resort I could just head over to the local fabric store and pick up some foam and pleather I suppose.

Our seat, in desperate need for some upholstery.

For the next few steps I’m going to get going on getting the rear wheels mounted permanently with new blocks and get our chain back on and in business. I may have to make it longer with our remounted rear wheels.  If I can insure the front is solid (no cracks) then heck at that point we’d have a fully functional go kart and that would just be great.

If you happen to have any leads on some reproduction Schwinn bike headlights (chrome type) drop me a line.

Until next time…

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