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Go-Kart Chassis's Design and Construction Based On Theoretical and Experimental Findings PDF
Go-Kart Chassis's Design and Construction Based On Theoretical and Experimental Findings PDF
By
Ho Yoong Chow
making this paper such a success. Without their support and assistance, this
First and foremost, I would like to thank my supervisor, Mr. Syed Tarmizi
Next, my fellow group mates, Mr. Tan Tang Chin, Mr. Fam Kueh Szue,
and Mr. Rowdy Ignatius, who have been very cooperative and supportive to rne.
I would like to say thank to our CNC laboratory technician, Mr. Masri b.
Zaini and Mr. Rhyier a/k Juen, who supplement me the skill of operating and
By this opportunity, I would also like to thank Mr. Opec Kadri, owner and
Managing Director of Cosama Sdn Bhd, and Mr. Wan Azlan Shah, lecturer of
go-kart.
Finally, I would also like to thank my family, fellow friends and those
Ho Yoong Chow
UNIMAS, 2001
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Table Of Contents
Pages
Letter of Approval i.
List of Graph
Abstract XI.
Abstrak XI1.
1 Introduction 1
2 Literature Review 4
2.1 Introduction 4
2.3 Platform 8
2.4.3 Chrome-moly 11
2.5.2 Length 12
V
2.5.3 Steering Position Alignment
2.5.4 Kart Straightness
2.5.5 Other Jobs
2.6 Basic Go-kart's Chassis Theories
2.6.1 Frame Construction
2.6.2 Side Bite
2.6.3 Torsion Bars
2.6.4 Ackerman Steering
2.6.5 Kingpin Inclination
2.6.6 Spindle
2.6.7 Scrub Radius
2.6.8 Caster
2.6.9 Caster Stagger
2.6.10 Camber
2.6.11 Toe-in
3 Methodology
3.1 Data Collection From Research
3.2 Data Collection From Interview
3.3 Mathematical Analysis
3.4 Chassis Design Generation
3.5 Go-Kart Construction
3.6 Initial Chassis Setup
3.6.1 Chassis Baseline
3.6.2 Chassis Alignment
3.6.3 Initial Setup
3.6.4 Rear Axle
3.6.5 Rear Axle Mounting
3.6.6 Spindle Installation
3.6.7 Front And Side Bumper
3.6.8 Seat Installation
3.6.9 Floor Pan
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3.6.10 Weight Distribution 4 *1
3.7 Chassis Material Testing 45
3.8 Evaluation Of The Final Product 47
4.8 Camber 56
Engineering Properties.
vii
List Of Figures
Pages
viii
3.3 Kart Data for Windows 95/NT used in calculating the weight 29
distribution on a go-kart.
3.4 Kart Setup by Kyle Davidson. 30
3.5 Designing software for generating drawing of the new 31
chassis- AUTOCAD R14.
3.6 Worktable. 32
3.7 The worktable specially constructed for building the chassis. 33
3.8 Process of heating up the steel pipe for bending process. 34
3.9 Bending process of the frame. 34
3.10 Figures showing steel pipes which have been welded 35
together to make up the outer frame of the chassis.
3.11 Completed frame. 36
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List Of Tables
Pages
List Of Graph
Pages
X
Abstract
The best way to evaluate a functioning go-kart would be testing its performance
under various conditions and points. Therefore, a new go-kart called MechTech-
Mech Tech -Initial was constructed based on the common go-kart size
found in the market but with slight difference in the frame design. MechTech-
Initial's chassis was built using steel pipes, bent and welded together, with
system, bumper and wheels are mounted to the chassis to test the performance.
The chassis dimensions were taken for further testing and future
reference. Among the tests applied are weight distribution on each wheel, and 17
degree method.
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Abstrak
Cara yang paling berkesan untuk menguji persembahan sebuah 'go-kart' adalah
dibawah pelbagai keadaan dan kedudukan. Maka, satu 'go-kart' yang diberi
Mech Tech- Initial telah dibina berdasarkan ukuran go-kart yang lazimnya
steering, brek, bampar dan roda kemudiannya dipasang ke atas cesi untuk
menguji persembahannya.
Dimensi cesi diambil secara teliti untuk tujuan kajian lanjutan dan rujukan
masa depan. Antara kajian yang dijalankan adalah penyebaran berat pada setiap
X11
1 Introduction
automobile racing has become one of the most popular sports among
wheels. But, it was not fully implemented in racing activity until the past
three hundred years in America. The first go-kart was simply a cart
using 100cc mower engines and strong steel frames. Then, newly
designed karts were beginning to gain popularity in Britain around the year
1959-, i960. Go-kart has long existed in our world whether used in sport or
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ground, two of which control the steering while the other two transmit the
power. Its main parts are the chassis (which consists of a body frame work
that is made up of a set of bent steel pipes that are welded together) with
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Formula One. Today, go-kart racing is not only practiced by adult hut the
Practicing on go-karting can properly expose the driver to the actual racing
continued growth every year, and the manufacturers who have stayed with
techniques, this sport would surely obtain a very high ranking of popularity
2.1 Introduction
Usualiy a go-kart driver or owner who wants to improve the handling of the
vehicle will purchase the latest in wheels, tyres and other optional
equipment, but end up finding that those things in fact handles worse. The
first stage in achieving a good handling kart that will provide the greatest
final drive components) are mounted to the chassis. The chassis would
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television are built (Oxford Advanced Learner's Dictionary, p. 190). There
are three basic designs used today: frame, unit-body, and space frame
construction.
supports all the `running gear' mounted on it, including the engine,
transmission, rear axle assembly (if rear-wheel drive), and all the
suspension components.
complete that most karts can usually be driven without the body.
Ladder Frame
This type of frame is common for the type of perimeter frame where the
show as a ladder frame sample where viewed with the body removed. The
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Perimeter Frame
the entire perimeter of the body (Figure 2.2). The frame members will
provide support underneath the sides as well as for the suspension and
suspension components.
Stub-Type Frame
Troy, Michigan, that does not use a separate frame. The body is built
strong enough to support the engine and the power train, as well as the
suspension and steering system. The outside body panels are part of the
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I. i
Figure 2.3 (a) Unitized construction, the small frame members are for
the body and do not required the rear frame section; (b) separate body
such a way that the body is combined with the structure of the frame. The
body itself supports the engine and driveline components, as well as the
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suspension and steering components. The body is composed of many
provides sufficient strength to withstand high stress but also the stability of
the vehicle during any performances. The typical vehicle uses 300
separate and different stamped steel panes that are spot-welded to form a
vehicle's body.
structure of the body to support the engine and drivetrain as well as the
framework for the entire vehicle. The vehicle using this type of framework
is drivable without the body. It would only uses plastic or steel panels to
2.3 Platform
The platform of any vehicle is its basic size and shape. Various vehicles of
different makes can share with same platform and, therefore, many of the
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A platform of a unit-body vehicle includes all major sheet-metal
include the front suspension and engine supporting sections. The area
called bulkhead. cowl panel, dash panel, or firewall. The height and
and ride are the track and wheelbase of the vehicle the track of a vehicle is
the distance between the wheels, as viewed from the front or rear. A wide-
track vehicle is a vehicle with a wide wheel stance; this increases the
vehicle is the distance between the centre of the front wheel and the
centre of the rear wheel, as viewed from the side. Vehicle with a long
Most of the automotive components and parts are made of cast iron, such
as brake drums and rotors, spindles, engine blocks, and many other
components including fasteners. There are different types of steel for each
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material. The amount of carbon in steel is the most important point in
Galvanized steel is steel with zinc coating which could protect the steel
and zinc.
High-strength steel (HSS) has been introduced widely since the mid-
1970s, as many car and light truck parts have been built with it. Application
of HSS is commonly in the sill area under the doors where high strength is
HSS is very hard, but heating causes it to lose much of its strength.
1O
2.5.2 Length
It can be done by heating the front axle and twist the top of the king pin
with the greatest lean back to a more upright position to match the other
side.
The next step would be aligning the steering position. Firstly, the rims of
the front wheels must be machined so that the inner and outer diameters
on both wheels are all exactly the same size. Then, it is possible to use a
The steering shaft in most modern karts is offset to the brake side
of the kart. With the wheels fitted, it is necessary to find the difference from
the centre of the steering shaft at the steering yoke to the inside of each
front wheel level with the steering arm on the kingpin. This amount of
offset should then be built into the tie rods when the steering yoke is at
the toe in and toe out desired can be adjusted by equa; ly lengthening or
shortening both tie rods. However, the straight edge should first being
placed across the machined wheels to check that both are set on the
same amount of camber before setting the toe in. Front wheel alignment
should only be done if the camber is equal and at the desired angle.
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2.5.4 Kart Straightness
The kart should be check if it is twisted. With the kart positioned on a flat
floor, place the wheels and tyres back on the kart and with the tyres
correctly inflated, then using a set of scales lift each front wheel by
hooking the scale hook around the king pin. Then spin the wheel lifted and
slowly lower the kart until the wheel touches the floor and note the amount
of lift needed at the point of contact. Each side of the kart should require
the same amount of lift. If this is not the case, the chassis is twisted. To
correct the situation, place the rear wheel on the same side, as the kart is
light at the front and with someone standing on the opposite rear wheel
twist the light front side of the kart down. This should be repeated until the
both front wheels carry the same amount of weight. Once the front is even
the back will also be even (idea quoted from http: //arkweb. com/karting).
Firstly, try centering off the chassis tubes and then checking the axle
diagonally with the tops of the king pins to check if the chassis runs out of
line in the centre. If fault was found with the diagonal check in the chassis,
it is best simply offset the axle slightly. Once this is done, the ends of the
rear axle can be used accurately for setting the position of the rear hubs.
With all the previous 4 jobs done, some other minor activities should then
be carried out. First clean and oil every bearing and moving the chassis
where necessary by removing it from the chassis. Make sure each moving
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part is in good condition or otherwise, replace it if doubtful. Make sure that
all king pin bearings, steering shaft bearings, tie rod ends, wheel bearings
and axle bearings have a good fit and not sloppy. Finally, check the kart
for any cracks and repair where necessary before putting everything back
together.
Once all the steps have been completed, think about setting up for
is also the karters responsibility to stay within the sprit and intent of the
Setting up a good go-kart chassis requires not only the knowledge of basic
theories but also from past experiences. Theories will help beginners in
setting their first go-kart but experiences would help further improve it.
The most important aspect in the frame of a go-kart would be its flexibility,
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Some flexibility is good for a go-kart and even makes setting up
easier, but over the time the frame may not rebound back to its original
are only good for about 18 months before replacement is needed. Racing
on the same track week after week would cause the frame to take a set,
which diminishes its flexibility. One of the easiest ways to alleviate this
track.
Site bite is the ability of the go-kart to stay stuck on the track without
sliding when going around a corner. With the correct amount of side bite,
the go-kart would unload the inside rear tyre when taking a corner which
will reduce the effect of scrubbing the tyres. However, too much side bite
would cause a hop or bicycle around the corner or scrub off so much
speed causing the engine will bog down. On the other hand, too little side
The design of the go-kart frame itself has a lot to do with how much
side bite it has. One good indication is by measuring the width of the rear
frame rails. A narrow kart would measure 24" to 25" while a wider kart has
a series of torsions bars welded together. The shorter the bars and the
more triangulation, the stiffer the frame will be. The frames flexibility can
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