Go-Karts are one of the most enjoyable rides you can have – especially if you’re the one to build it from scratch! There’s no satisfaction like creating something with your own hands. And with go-karts, you can even fully enjoy the end product! You’ll have a better feel and control for your kart and you can customize it to make it your own. And most importantly, go-karts are cheaper built than bought! But before you dive into the art and science of building your own go-kart, there are several things you need to consider.

Do You Have What It Takes to Build Your Own Go Kart?

First, you’ll need to have basic mechanical knowledge. You don’t need to be a professional mechanic. Contrary to popular belief, go-kart building is hobbyist and amateur gearhead-friendly. Next, you need to consider the purpose of the go-kart. Do you want to use the go-kart solely for casual rides around the neighborhood? Do you want to create a go-kart that can pull wagons around? Or do you have professional races in mind? You’ll need to optimize your go-kart build for your specific needs. Parts for regular go-karts differ from parts for racing go-karts in quality, design, and price.

Aside from purpose, you also need to consider the go-kart’s prospective rider’s age, size, and go-kart driving experience. One of the key selling points of DIY go-karts is that you can fully customize the kart to suit the driver’s size, height, personal preferences, and experience level.

One of the most important build considerations is the kart frame. Though highly customizable, you should build go-karts according to industry-tested parameters and tolerances. You can purchase frame kits but DIY frames will enable you to customize them according to the specifications of other parts. What you need to focus on is the strength and structural soundness of the frame.

Technical considerations include types of engine and engine power. There’s the option of either a gas or electric engine motor. Both have their advantages and disadvantages. Electric engines are relatively easier and cheaper to maintain since they don’t have many moving parts that will eventually wear out.

And of course, electric engines are more environmentally friendly as they don’t use petroleum-based fuels so they don’t contribute to the toxic emissions in the atmosphere. Performance-wise, electric engines are quieter but a single charge on an average electric engine will only last for more or less 20 minutes. You also need to invest in a more expensive engine to get the same speed and power as gas engines.

Other things to consider are the amount of time, effort, and money you are willing to spend on your go-kart build. The more time you dedicate to building the go-kart, the faster you can enjoy the fruits of your labor. But if you have little time to spare and you don’t have the patience to build your go-kart piece by piece, you may need help. And if you want to make the most out of your budget, you can always opt to buy used parts. This is, of course, after considering the purpose of the go-kart.

How Much Does it Cost to Build Your Own Go Kart?

With all these considerations in mind, building a go-kart from scratch can take anywhere from 3 days to a month and can cost around $400 to  $4000. It all depends on you if you’ll enjoy the process and make this project a memorable one!

How to Go About Building Your Go-Kart

To make this guide easier to follow, we divided the build guide into 5 sections: Assembling the 4 Main Parts of the Go-Kart, How to Create a Frame for the Go-Kart?, Selecting and Sourcing a Go-Kart Engine, Must-Have Parts for a High-Performance Go-Kart, Tires, Wheels, Seat, and Go-Kart Brakes. Here is also a cool video for you to watch before you start-

Assembling the 4 Main Parts of the Go-Kart

Building a go-kart is more than assembling parts, but the process begins with determining how to assemble different parts of the go-kart. For a basic go-kart build, you’ll need to assemble 4 different sections of the kart and install other essential parts in this order:

1. Front A-Arms (Control Arm)
2. Mainframe
3. Steering System
4. Drive Axle
5. Other essential parts of the go-kart build

Pro-tip: Double-check the measurements of individual parts before assembly. Metal parts should be an exact fit, especially on structural sections of the go-kart. Lay down the pipe steel and measure each piece’s length and width before welding. It is not advisable to perform multiple welds on a single section as it can create failure points that can compromise the structural integrity of the build.

Assembling the Front A-Arms

1. You can use or create your own template or rig to ensure the accuracy of the A-Arm construct. The rig can be as simple as scrap pieces of wood screwed onto a board or nails outlining the general structure of the A-Arm. Not only will the rig ensure accuracy, but it will also provide secure support for the tubes and prevent warping during welding.
2. Connect the A-Arm to the mainframe with the use of nuts and bolts. Ensure that these nuts and bolts are the right sizes and that you place a washer in between the nut and bolt.

Assembling the Frame

1. As with the front A-Arm, you can use a jig with clamping capabilities for your go-kart frame. This will ensure that everything is secure, square, and accurate before you weld each joint.
2. Use a tube bender tool to create bends for the front bumper mount and roof frame. The tool can be tricky to use for beginners but all you need is to determine the locations of each bend and that each bend has the same length and angle.
3. Adjust the mainframe to be wider at the back. This is to prevent the rear axle from bending due to the distance between the bearings and the rear wheels.
4. Also, ensure that you have adequate space for your front wheels. The tires should not rub on the frame as they move.
5. Double-check the accuracy of the frame size by arranging the seats to their respective positions. Also, take into consideration the size of your engine. 4-stroke engines are usually wider than average racing go-kart engines so they can’t mount on the side of the go-kart.

Assembling the Steering System

1. The steering angle should be correct and enable the driver to assume a comfortable driving position.
2. Assemble the steering column with the steering wheel bolted into the column through a steel hub and the pitman arm pointing up on the bottom of the shaft.
3. Weld or bolt the steering column’s bushings or sleeves under the steering hoop to secure it in place. Usually, the steering hoop will be at a 55-degree angle with its ends welded directly to the frame.
4. As you connect the steering shaft’s lower bracket to the steering rack, make sure to first check the steering angle. The pitman arm should not turn over 45 degrees left and right.
5. You can convert steering racks from select car models for use on your go-kart build.
6. You can either weld or bolt the steering column in place. Most often, bolts and nuts are used to secure steering parts.

Assembling the Drive Axle

1. You’ll need a differential with a sprocket with 13 teeth and an axle with 9 teeth.
2. You can use a #50 chain link to increase the speed compared to the average speed of lawnmowers and other small vehicles that use the same differential.
3. A chain guard is necessary to prevent the chain from falling off. It’s also important that the chain is adjustable.
4. Ensure that the bearings are the proper size for the shaft and that the wheels and tires are suitable for your cart. These two parts can make or break your go-kart’s performance.

Other Essential Parts of the Go-Kart Build

You can easily assemble the main structural parts/sections mentioned above, but there are also essential parts that you only need to install. These parts include the engine, steering shaft, spindles, tie rod, and pitman arm. To complete the build, you’ll need brakes, seats and seat belts, tires and wheels, sprockets, and torque converter or centrifugal clutch.

How to Create a Frame for the Go-Kart?

Now that you know how to assemble go-kart frames, you may have questions regarding your options. Is there only one way to build a go-kart frame? The answer is no! You actually have the options on what types of steel to use and how you can use them to make your go-kart more structurally sound and cost-efficient.

2 Types of Steel for Go-Kart Frames

1. Pipe Steel – These round pipes are the most commonly used type of steel in go-kart frames. They create an aesthetically pleasing outline, especially the bent sections. One disadvantage of this type of steel is that it’s difficult to work with. Welding these pipes can also pose some challenges.
2. Square Tubing Steel – Square or angular steel is a perfect alternative to pipe steel. It’s relatively easier to bend and weld together. Another advantage is that it is cheaper compared to pipe steel, making it a perfect material for hobby welders. But one drawback of the square tubing is that the end result isn’t as neat and aesthetically pleasing as pipe steel.

Welding the Go-Kart Frame: Tips and Tricks

Did you know you can weld pipe and square tubing together? Also, remember these tips before you dive into welding and cutting parts not only for your go-kart frame but also for other parts of your go-kart build:

1. Safety should be your foremost consideration. Don’t forget to wear proper protective gear such as a welding helmet, flame, and heat-resistant welding gloves or gauntlet cuff gloves, and welding aprons.
2. Only cut or weld in a well-ventilated and spacious area.
3. Accuracy is vital. Before welding or cutting, ensure that the pieces fit together and that the measurements are accurate. To avoid unnecessary movement, secure the pieces flat on your working table with welding clamps. Check for the accuracy of the pieces’ position with a square.
4. Test the strength of the welded joints before the final assembly. The joints should be able to withstand high torque, especially during rough rides.
5. Inspect the welded joints for cracks or other signs of failure after every test drive.

You don’t need high-end welding equipment to assemble a high-quality go-kart frame and Front A-Arm assemblies. Though not for total beginners, go-kart builds do not require steep learning curves.

Selecting and Sourcing a Go-Kart Engine

I know, this is where many people give up, but no need to be. Essentially there are two types of engines you can use on your go-kart: air-cooled engines and water-cooled engines. Both types of engines have their advantages and disadvantages. An air-cooled engine is smaller with a simpler mechanism but it is prone to overheating. A water-cooled engine is more heavy-duty and does not overheat but setting it up can be tricky because of the risk of leaks.

Horsepower is another important consideration. Though most engines have an average horsepower of 8 HP, as much as possible source a 10 HP engine. A higher horsepower will enable you to create a high gear ratio for more torque and controlled/safe speed. Confused yet?

Aside from the type of engine, also consider the practicality and functionality of the engine. If you are after a basic hobby build and on a tight budget, opt for engines that do not need complicated adjustments or need additional parts and accessories. Most of the time, it boils down to your preference and the availability of specific engines.

But where can you source an engine for your go-kart? Here are just the most common sources of engines:

Small Vehicle Engines

Pros: These engines find use on a wide variety of small vehicles or motorized equipment including leaf blowers, golf carts, pressure washers, generators, small lawn and garden equipment, and even old go-karts! They can be readily available in stores and have more straightforward mechanisms, come out of the box with tanks, mufflers, and starters; and you can bolt them down the frame easily.

Cons: Though relatively smaller than other engines, most small vehicle engines don’t come cheap. You also need to install a clutch.

Lawn Mower Engines

Pros: Most of these engines have adequate power and torque to run go-karts. Just like other small vehicle engines, lawn mower engines are easy to source.

Cons: Forget about using this engine for racing go-karts. They’re slower than other engines, can be difficult to install, and need extensive customization. Most of these engines have vertical shafts and horizontal drive wheels. You’ll also need a differential and an adapter to transmit power to your wheels efficiently.

Snowmobile Engines

Pros: Easy to source in specific areas. They are also cheap and have relatively high torque.

Cons: This engine will immediately overheat during hot weather. You’ll need to install a radiator, fan, and relays for the engine to work for this purpose

Motorcycle Engines

Pros: Both 2-stroke and 4-stroke motorcycle engines are highly suitable for go-karts. Small 250cc to 500cc single-cylinder motorcycle engines adaptable on any size of go-karts.

Cons: They’re often more expensive than other types of small engines. You’ll need to customize mounting as they are bulkier and rarely come with tanks.

Car Engines

Pros: If you are planning to build a beefed-up go-kart, a car engine will provide very fast speeds and very high torque.

Cons: A car engine is overkill for a go-kart. Even if you plan to use the smallest car engine you can find, the engine will still be too heavy, bulky, and too much for a hobby build. It’s also too expensive and requires the installation of a clutch, an original transmission, a customized drive system, a radiator, a fan, a heavy-duty frame, and constant tire changes.

Please note that not all motorized vehicles/equipment use the same type of engine. Research the specifications of an engine, especially when buying a used or rebuilt engine. Also, not all aspects of engine setup and repair can be DIYed. If you don’t have experience mounting the engine and installing its parts, you need to seek help from a professional to avoid hiccups.

Must-Have Parts for a High-Performance Go-Kart

Now that you are done with the front A-Arms, mainframe, steering system, drive axle, and the engine, it’s time to go back to other essential parts of your go-kart build. This includes 4 parts of the steering system that are vital in the efficient performance of your go-kart. These parts include the steering shaft, spindles, tie rod, and pitman arm. But how can these parts contribute to your go-kart’s performance?

• Steering Shaft – This is the section starting from the steering wheel down to the bottom of the pitman arm, connecting the steering wheel to the steering gearbox. It controls the movement of the wheels, stabilizes the steering column. A steering shaft that has connection issues with the steering gear will cause difficulties in turning, a steering wheel that feels loose and misaligned, and grinding/clicking noises during steering.
• Spindles – The spindles or front axles are important steering components that connect the axle to the hub. The spindle assembly is for the driver or passenger side and serves as a steering connection.
• Tie Rods – Another vital part of the steering assembly, tie rods connect the front axles to the pitman arms. Unlike other parts in the steering system, the tie rods are adjustable. You can adjust the “toe-in” amount of the linkage to enable the go-kart to turn easily. A slight toe-in is more suitable for go-karts as it aids in lifting the inner side of the tire during turns.
• Pitman Arm – Located at the bottom of the steering shaft and connected to the tie rods, the pitman arm pushes the tie rods to the direction dictated by the steering wheel. Its connection to the steering shaft means the pitman arm only moves when the steering shaft turns.

Tires, Wheels, Seat, and Go-Kart Brakes

Now that you’re near the end of your build, you need to take into consideration what type of tires, wheels, sprockets, seats, and seat belts. You’ll also need to decide whether you should use a torque converter or centrifugal clutch. To make the process easier, we compiled parts recommendations for you.

Considerations in Selecting Tires and Wheels for Your Go-Kart Build

• A majority of go-karts have larger rear tires. Traditionally, 4.10×3.50 tires are used with 4 inches to 6 inches wheels. These are easily available in the market.
• Though you can convert a tubeless rim to mount tubed tires and vice versa, it is advisable to only use tubeless tires on tubeless rims.
• Different types of tire treads offer their advantages and disadvantages, but for longevity and better traction, ribbed tires are superior
• Wheel assemblies with 5/8” bearings are more preferable as this size of bearings have bolts that fit on 1 pipe steel tubing.
• Also, high-speed bearings are preferable for better and more reliable performance.

The Right Sprockets for Your Go-Kart

Easy to install, more durable, and cheaper, chains and sprockets are preferable to pulley systems. For go-karts, the most popular sprocket sizes are 35, 40, 41, and 420 chain pitch. Larger sprockets improve the low-end power while smaller sprockets improve the top-end speed. You need something in the middle as small sprockets weaken the kart’s low-end torque. Some compromise by using torque converters.

Selecting the Right Brake for Your Go-Kart

There are 4 types of brakes you can use on your go-kart build: scrub brake, band brake, drum brake, and disc brake.

Scrub Brake – Most of the time, scrub brakes are adequate but they can be hard on the kart’s tires. They’re the brakes with two metal paddles or a braking bar. The way these brakes work is that the paddles press against the rear tires. Converting the scrub brake into a hand-activated brake bar often puts too much pressure on the tires.

Band Brake – Simple and cheap but with a significant setback: it won’t work well when wet. The way this brake works is that it uses a metal band that constricts around a brake drum, stopping the motion of the wheels.

Drum Brake – This brake has the opposite mechanism as the band brake. Instead of constricting a brake drum from the outside, the drum brake swells from the inside of the brake drum. As the braking mechanism isn’t often exposed to the elements, they often last longer and provide better braking action.

Disc Brake – Probably the best braking solution for go-karts, disc brakes provide premium-quality braking technology and durability. This also makes disc brakes pricier. A cheaper substitute is a drive sprocket (in place of the brake disc). It can provide a similar stopping ability but drive sprockets need constant maintenance.

Go-Kart Seats and Seat Belts

Any kart seat new or old is suitable as long as they fit and serve their purpose. The most common type of seat used on go-kart builds are bucket seats made from either hard plastic or fiberglass. And they’re popular for a good reason; they’re highly durable and easy to maintain. Upholstered seats may offer more comfort but they require care and more thorough cleaning.

But go-kart seats won’t be complete without the compulsory seat belts. You have two seat belt options: 3-point harness and 5-point racing seat belts. The former is the most common type of seat belt used on passenger vehicles but for optimum safety, especially in go-karting. You don’t need to shell out serious money for brand-new seat belts. Older versions of the 5-point racing seat belts are cheaper since new regulations mean that earlier seat belt designs are no longer allowed on professional races.

Should You Use a Centrifugal Clutch or Torque Converter?

A centrifugal clutch is a simple yet highly functional mechanism that reduces engine load by transmitting engine power to the drive wheel. This will enable you to maximize the power of your small engine. The centrifugal clutch has an outer housing with an attached sprocket. The clutch expands according to changes in centrifugal forces. When the clutch spins to full rpm, the clutch’s shoe will lock up with the housing, transferring the engine’s power to the sprocket and the chain. The clutch also allows the go-kart to go idle and not move as it disengages the sprocket.

Though a centrifugal clutch may work perfectly for your needs, a torque converter is a more efficient, albeit more expensive option. What is a torque converter, you ask? Torque converters work similarly to automatic transmission. It allows smoother acceleration and higher speeds out of a small engine with low horsepower. A torque converter has a belt and two pulleys that work in conjunction, shifting gears according to the go-karts speed. The converter automatically shifts to low gear at low speed to create more power and torque. At high speeds the pulleys shift create a lower gear ratio, providing more speed and climbing power. So, instead of buying a more expensive engine with high horsepower, you can give your low-horsepower engine with a torque converter.

Safety Concerns in Building Your Own Go-Kart

At the end of the day, safety should be your priority. Don’t let mishaps cut your fun. Whether you are building a go-kart for a ride around the neighborhood, fun races on your property, or for entering a racing circuit, you need to observe the same precautions when building your own go-kart.

1. Opt for parts, especially engines specifically designed for use on go-karts or similar vehicles. Only modify mechanical or electrical parts if you have in-depth knowledge of the inner-working of machines.
2. Know the rest of cheap, used, or cannibalized parts. Even when they fit, there’s no assurance of their quality. Thorough testing is necessary to ensure that the cannibalized parts won’t fail while the go-kart is running. But as a rule of thumb, don’t always go for the cheapest options.
3. Installing mistakes can cause the build to fail or worse, cause a dangerous ride. Some engine mounts may seem straightforward but improper installations have direct effects on steering.
4. If you need to tip the engine on its side during installation, practice caution so that oil won’t spill on the carburetor. This is especially a risk in open-cell lawn mower engines.
5. Don’t expose parts to extreme weather. Extreme heat or cold is particularly hard for the engine. The engine and any electrical component can combust due to excessive heat while frozen engine oil can cause problems later on.
6. Wear proper welding equipment and always practice safety precautions when handling welding equipment. Also, go-kart builds are not suitable for absolute beginner welders. Even if you already have basic knowledge and experience in welding, it’s advisable to have someone to guide you throughout the process.