1. Engine And Passenger Layout

First of all the assumption, whether this go-kart is made out of wood or is made out of steel is that you have some sort of layout in mind. Typically the engine is behind, and the person sits in front of the engine. A good safe layout is to have a seat protect the passenger from the engine.

So a structure of some sort is needed to hold the seat in place. You can use a seat off of a chair, but a more protective seat is a ½ piece of plywood angled back and supported. Covering the piece of wood is optional, but it is more comfortable with basically a piece of heavy cloth covering a cushion. The cloth is stapled typically into the board (on the backside).

The structure supporting the seat can be wood, or steel.

The frame work can be wood or steel as well. If using wood, use two by fours placed vertically, so that the strength of the wood is optimized.

If you are using steel for the frame, use a tubing that is at least .070 wall or thicker. The length of the frame is really dictated by how big the person is. Have a person sit comfortably in the leaned back position with a steering wheel in their hands. That is the person compartment. Measure this length.

Add the engine drive section and the person compartment lengths together and that is the length of the gokart. Cut your frame tubes (or tack tubes together) to this length. You will need at least two parallel lengths of tubing.

Space the tubes apart the width of the seat you made (20 inches is a good width).

Cut at least four (4) tubes to the 20 inch length. Lay all the pieces on the floor. Place the 20 inchers at the following locations: Engine Plate area, seat back section, seat forward section, front main bumper tube, and rear main bumper tube. (The bumper tubes can be wider than the frame by 12 inches (6 inches per side).)

Tack the tubes in place using a welder. If you do not have a welder, then you can fasten them together using plates and bolts. (Trust me, buy a $100 welder and save yourself wood chips and drill bits, busted knuckles and exasperation!)

What you have put together now is what I term a "flat-go kart." You will soon find out that flat gokart frames are weak and require extra stiffening. You may want to put some struts into the system to bolster the frame design. Typically what I use is the seat back as reference. This works very well as an integral frame support, side seat holder, and engine protector.

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