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Base frame
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The base frame is ready for assembly.
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The first thing to be assembled is the roll bar. The front bars are assembled with the front plate.
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Roll bar
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Frame and front bars
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The front bars are reattached to the frame. The bolts are not tightened until all the parts are installed.
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The top plate and rear bar are next to go on. Once everything is installed and the bars are squared up, all bolts are torqued.
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Rear bar next
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Frame assembled
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Some foam pipe insulation was installed on the bars next to where the seat goes. This will help cover the bolts and give a little padding. The frame appears to be growing with the bars installed. The dog likes it.
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The spindles are reassembled with new hardware. The pivit points are greased up with a moly grease.
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Spindles
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Tie rods
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Tie rods are greased and installed. Final adjust will be made after everything is together. The steering shaft was also oiled.
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The front suspension is complete. Final adjustments will be done when the cart is completed.
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Front suspension
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Engine installed
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The new Tecumseh 5 HP engine is installed.
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The clutch was changed out for a Comet Torq-A-Verter to get the most out of the engine. The engine was shimmed too much in this photo, and has been corrected.
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Axle and torque converter
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Rolling chassis
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The tires are installed so the kart can be put on the ground while waiting for other parts.
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A rubber floor mat was made and glued to the floor for a finished look.
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Floor mat
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Steering wheel
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The wheel is bolted on. The stop switch was mounted on the wheel for easy control in case the cart needs to be shut down quickly.
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The wiring to the switch were routed through the frame to the rear of the cart.
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Switch
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Seat
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The seat is bolted in. This is a Manco seat and head rest, so everything lined up fine. I had to drill a hole on the mount strap that was replaced on the frame.
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The brake band is bolted up and connected to the control rod. A return spring is added to retract the band.
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Brake
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Brake pedal
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The brake rod is assembled to the pedal. There are extra holes in the pedal and rod to make adjustments as the brake band wears.
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The throttle cable is assembled to the engine. The control was changed from the "lawn equipment" hand control to a Power Sport unit that allows a cable to operate it, and spring back to idle.
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Throttle hook up
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Throttle pedal
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The throttle is assembled at the pedal. The cable is adjusted for full actuation of the engine control. A return spring is installed to ensure full throttle closure. There is a spring on the engine control, but the second one is for extra safety and a better feel.
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This cart is done aside from some testing and tuning. Some more minor adjustments and tweaking is needed.
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Complete
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