Fabrication Practice and Techniques for Go-Kart

Abstract

This paperis focused on the fabrication of a high-performance go-kart using suitable material. The main objective is to construct a robust and lightweight chassis that can withstand the extreme hard conditions of racing while ensuring safety and performance. The fabrication process will involve cutting, welding, and assembling various components, including the frame, engine mounting,axles, and steering system. The project will explain the step-by-step fabrication techniques going to be used, including the selection of appropriate tools and equipment, as well as safety measures to be followed during the process. Special attention is given to precision in measurements and weld quality to ensure structural integrity with possible cost efficiency

Introduction

This paper focuses on the fabrication process of a Go-Kart built in compliance with the 2024 ISNEE Motorsport’s GKDC rulebook, emphasizing safety and innovation. The main goal is to design and build a strong, lightweight, and efficient Go-Kart using appropriate materials and fabrication techniques while enhancing mechanical and problem-solving skills.

Key Highlights:

1. Methodology & CAD Modeling:

• A structured fabrication process is followed, beginning with CAD modeling in SolidWorks 2024.

• CAD models help in pre-fabrication testing, reducing cost, improving design efficiency, and avoiding potential failures.

2. Material Selection:

• AISI 4130 Chromoly steel is selected for the chassis due to its high strength-to-weight ratio, weldability, and ability to withstand impact.

• Other materials used:

  • EN24 for shafts (strong and durable)

  • Cast iron for wheel knuckles (stress handling)

• Circular tubes are chosen over square ones for better torsional strength, even stress distribution, and ease of repair.

3. Fabrication Techniques:

• Cutting: Done using an angle grinder for quick, low-cost cuts.

• Bending: Uses rotary draw bending for high precision and cost efficiency.

• Machining & Drilling: Lathe and drill machines are used for making parts like axles and brackets.

• Welding: MIG welding is selected for its strength, clean finish, and precision—ideal for thin metal tubes.

• Finishing: Surfaces are ground smooth and coated with primer to prevent corrosion.

• Final Assembly: All components—steering, suspension, engine mounts—are integrated carefully, followed by final inspections for fit, alignment, and safety.

Conclusion

The fabrication of the go-kart project has successfully done with the application of engineering principles and hands-on skills. Through careful design, material selection, proper fabrication processes and assembly processes, functional and robust vehicle is developed that meets performance expectations and also satisfies the preferred rulebook.

References

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Copyright

Copyright © 2025 Mr. V. D. Dhopte, Prasad Chitade, Tanmay Dhabekar. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.