How to Build a Go Kart Powered by a Free Pressure Washer Engine

Introducing the Pressure Washer Go Kart Project

If you have an old pressure washer sitting around collecting dust, and an extra go kart frame in the garage, you may be able to combine them to create a unique and exciting homemade go kart! With some mechanical skills and creativity, these free materials can be transformed into a drivable vehicle for zooming around your property.

In this DIY project guide, we'll walk through how to mate a pressure washer engine to a go kart frame to produce a motorized #gokart on a budget. Read on to learn about planning the build, adapting the parts, fabrication and assembly, and finally taking your pressure washer go kart for a spin when finished.

Preparing for the Pressure Washer Go Kart Build

Before getting started on a build like this, you'll need to source the necessary materials and tools. Having a free pressure washer available will provide the engine, pump, and frame components to power your go kart. You'll also need a go kart frame which can often be found cheaply secondhand, or built from scratch out of steel tubing.

In terms of tools, you'll need typical garage tools like wrenches, sockets, pliers, screwdrivers, a drill, welder, and grinding wheel at minimum. A chop saw, vise, and bench grinder can also come in handy. Safety gear like gloves, eyewear, and a mask are a must as well.

Setting aside a proper workspace is also key before you start fabricating. This project will require some disassembly, test fitting, minor fabrication and welding, so be sure you have room to spread out.

Adapting the Pressure Washer Parts

The first stage of this build is to determine which pressure washer parts can be adapted to power and steer the go kart. At minimum, you'll want to utilize the engine, fuel tank, and pump. The engine will provide power to drive the rear wheels. The fuel tank stores the gasoline needed to run the motor. And the pump can be connected to a custom nozzle to provide steering.

Start by removing these core components from the pressure washer frame. Keep all the mounting hardware, brackets, fuel lines, control cables, and anything else that may allow you to adapt them to the go kart frame later on.

You'll also want to remove the pressure washer's wheels and axle components. The rear axle and wheel hubs can potentially be mounted to the new go kart frame.

At this stage, you should have the main pressure washer parts separated so they can be test fitted onto the new frame.

Fabricating and Assembling the Go Kart Frame

Next up is fabricating a custom go kart frame that will bring all the components together. If you are starting with a pre-made frame, it will need to be modified to mount the pressure washer engine, fuel tank, controls, and axle.

Some frame fabrication using tubing or metal plate will likely be required to create sturdy mounting points. Take measurements and test fit the parts as you go for proper placement. Consider the overall weight distribution as well when locating the components.

Welding is typically required during go kart fabrication to join the tubing pieces. If you don't have welding experience, seek assistance from someone who does, as proper welds are crucial for safety.

The steering system will also need to be adapted or fabricated from scratch. The pressure washer's pump can power a nozzle placed near the front which redirects thrust to steer left and right.

Integrating throttle and brake controls is another important step, allowing you to manage speed. With some clever fabrication, you can mount the pressure washer controls onto the go kart configuration.

Fabricating the frame, mounting all the components, and integrating the steering and controls takes skill and patience. But after lots of grinding, drilling, test fitting, and welding, it will start to come together as a drivable go kart.

Completing and Testing the Pressure Washer Go Kart

After the major fabrication is done, there are still some finishing steps to perform before starting it up. Double check all the mounting hardware is tight. Connect the fuel lines to the tank and engine. Make sure all controls are connected properly and functioning.

Add a suitable drive sprocket and chain to send engine power to the rear axle. Consider adding chain guards or other protective covers to shield moving parts.

With everything assembled, fill the gas tank, and try turning the engine over. Troubleshoot any issues if it doesn't start. Adjusting the throttle linkage or choke may help get it running properly.

Once running, thoroughly test the brakes and steering at low speeds. Have a fire extinguisher on hand in case of failure. If anything seems amiss, stop and readjust before continuing.

Provided everything checks out, advance the throttle further to enjoy your homemade pressure washer go kart. Just be sure to test it in a spacious area without obstructions. Make adjustments so it handles safely at higher speeds.

With that, you now have a unique motorized go kart powered by a recycled pressure washer! Let the tinkering continue as you refine and add custom details that make it your own.

Safety Tips for Operating Pressure Washer Go Karts

Creating a motorized go kart from a pressure washer and spare parts can be a fun and rewarding DIY project. But before taking your contraption out for a spin, it's crucial to prioritize safety.

Here are some key tips for safely operating a pressure washer powered go kart:

Wear Protective Gear

Be sure to always wear a helmet when riding in a go kart. Sturdy footwear, gloves, long sleeves/pants, and eyewear are also recommended for protection from debris or in case of falls at higher speeds.

Enforce Passenger Limit

Only allow as many riders as the go kart was designed for. Extra weight can affect braking, steering, and stability which could lead to an accident.

Drive in Open Areas

Pressure washer go karts are best suited only for off-road usage in large open areas with flat terrain. Avoid driving on roads, near traffic, or where you could hit obstacles and people.

Learn Controls Before Driving

Take time testing throttle, brakes, and steering at low speeds before advancing to higher speeds. Know how the go kart handles so you can control it properly when driving faster.

Check Mechanical Condition

Inspect your go kart thoroughly before each drive. Look for loose parts, leaks, worn brakes, damaged steering, and any other issues to address before operating.

Don't Perform Stunts

With a homebuilt go kart, avoid risky maneuvers like jumps or high-speed turning. Stunts raise the chance of instability, falls, and torque overloading components.

Watch Fuel Level

Monitor the gas level in the pressure washer engine and safely refuel when running low. Never overfill the tank to avoid spills and potential fires.

Building and operating a pressure washer go kart takes mechanical know-how and common sense. Following basic safety practices will help you enjoy the thrill of driving your creation without undue risk.

Customizing and Improving Pressure Washer Go Karts

One of the great things about DIY go karts is you can customize and expand capabilities over time. Here are some ideas for enhancements to pressure washer go karts using fabrication skills:

Add Roll Cage

A roll cage made from tubing will improve safety by protecting occupants if the go kart tips over. It also provides mounting points for seats, controls, and accessories.

Upgrade Suspension

Basic go karts typically have no suspension, but you can add shocks and struts to improve ride comfort and handling. Custom fabrication is required to integrate suspension components.

Improve Brakes

Larger brake rotors, calipers, and pads will increase stopping power. Hydraulic brake systems offer better braking control than mechanical linkage systems.

Add Body Panels

For a unique look, you can fabricate and attach custom body panels. Steel, aluminum, or even plywood sheets can be cut and formed onto the main go kart body.

Increase Engine Power

Swapping the pressure washer engine for a more powerful one requires adaption, but can significantly increase speed and performance.

Add Tuned Exhaust

Installing performance exhaust headers and mufflers can optimize airflow and power. But excess noise may be an issue for residential areas.

Include Trailer Hitch

Adding a rear hitch allows pulling a small trailer with your go kart, expanding functionality and cargo capacity.

Let your imagination run wild when it comes to enhancements and accessories for a custom pressure washer go kart. Just be sure to focus on safety and reliability when modifying your creation.

Maintenance Tips for Pressure Washer Go Karts

Proper maintenance is crucial to keep your pressure washer go kart running safely. Here are some key maintenance tips:

Change Oil Regularly

Refer to engine specs for proper oil type and change intervals. Fresh oil reduces wear and maximizes engine life.

Inspect Fuel System

Check for leaks around the tank, lines, filters, and carburetor. Repair any issues immediately to avoid fires.

Check Chain Tension

The engine-to-axle chain must have proper tension. Too loose can cause derailing, too tight leads to binding and wear.

Monitor Tire Pressure

Consistently low tire pressure affects handling. Use a pressure gauge and fill to recommended PSI when needed.

Check Fastener Tightness

Vibration can loosen nuts, bolts, set screws, and parts over time. Take time to spot check and retighten them.

Clean Air Filters

Dirty air filters restrict airflow to the engine, reducing performance. Regularly clean foam or paper filters.

Touch Up Paint

Spot paint any scrapes or rust areas on the frame to maintain the finish and prevent further corrosion.

Diligent maintenance like this will maximize reliability and longevity so your homemade go kart stays running strong.

Conclusion

With some DIY spirit and fabrication skills, an old pressure washer and go kart frame can be combined into a unique motorized vehicle for off-road fun. Adapting the engine, drivetrain, controls, and hardware takes planning and work. But the result is a one-of-a-kind machine to zoom around your property.

Focusing on sound construction and safe practices are paramount with homemade go karts. Add personal touches over time or leave the vintage pressure washer look. Either way, this budget #gokart mashup creates a customizable ride to enjoy solo or with fellow hobbyists and #mechanics. Just be sure to maintain it properly so the fun lasts for years to come!

FAQs

What size engine is best for a pressure washer go kart?

Smaller engines in the 5-10 HP range are well suited for powering lightweight go kart frames. Bigger engines can be used but may require beefed up frames and more fabrication work.

Can I use a battery-powered pressure washer for a go kart?

Electric pressure washers don't provide the sustained power required for a go kart. The small DC motors and limited battery capacity make them impractical for driving any significant distance.

Is registration required to drive a homemade pressure washer go kart?

Because these vehicles are homebuilt and not intended for road usage, registration is generally not required. But do check your local laws to be sure before operating your go kart.