Lee Bay wrote:

Been working on this for a while now, so thought I would share progress.

Stage 1

Bought a fibreglass j40 body shell from eBay second hand.

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So I had the shell, but what running gear and chassis. At first I thought petrol and bought this .

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But it was too big and powerful! So it went back on eBay.

Then I bought this, for £175! I didn't realise karts were so much.

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But it was complete, and I sold the engine for £200 as I was going electric, as the car was for both my boys.

So, the frame was too long and too wide. We cut and shut it to fit the shell.

We then mounted the frame for the motor, it's a 24v 500w. Electric motor.

The problem was the cog it came with didn't match my chain and axle cog, so I bought another.

The problem with that one is the shaft was 17mm and the cog was 15mm, and I couldn't drill out the cog, so we turned down the shaft to fit.

All good, but thegearing was all wrong. It was approx 2mph at 12v so 4mph at 24v was too slow.

So I made up a cog holder and mounted a larger drive cog.

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Now runs at 6mph at 12v!

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Lee Bay wrote:

So it ran,

Then fitting the electrics.

I had forward and reverse switch from eBay, but then had to fit a double pole, double throw switch to run it. Then I thought a bit laterally and fitted this.

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This has all the electrics, rated for 24v, will easily handle the amps, and has the benefit of being able to plug in a wander lead so I can speed control when my youngest is driving.

I disassembled a wander lead for the dash controls.

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The dash screws into the shell with two plugs for electrics. It has a key switch off, but the shell has to be removable to get it out the shed!

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Lee Bay wrote:

Hers the shell on the frame


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I had to cut down the front hubs as they wre too wide.

So here's the speed controller rated to 60amps

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Next step were tyres,

I had several sets, slicks and wets. I went with wets as they had more grip. But as it's a tot rod, I bought some tyre paint, and after several coats


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This also shows the complete set up, without the shell. I've made up some seats as well. All the electrics and moving parts are away from little fingers.

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Lee Bay wrote:

The shell is now with Steve (speed machine) unit for spraying.

So next step is the trailer...

It's built out of plywood and based on the style of a radio flyer cart


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It will have mahogany bars x3 on each side mounted to the pine pillars

The pic shows the rudimentary tow bar, which is now welded to the back of the chassis.

It's now been rubbed down and in the paint shop.

I have been busy on the wheels as well, need another coat..


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Lee Bay wrote:

It's been to speed machines paint shop and it's back!!

Steve has done a great job!


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And the trailer


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Now for decals, and final assembly.

Just ordered the batteries, £130!!!

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Lee Bay wrote:

Started on the trailer

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Added the mahogany sides

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Then screwed on

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With wheels, drawbar and lights

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Then started on the car

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Stickers, badge , handles and catches on

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Lee Bay wrote:

Now with headlights, steering wheel and seats.

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Still need to finish some bits off, but nearly there!

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