The wooden no-engine go-kart is a fun toy to build and drive. As there is no engine the go-kart is gravity-powered and rider-controlled, therefore a steep slope is needed to ride the go-kart. The fun of the wooden go-kart often comes from building it with children and watching the kids race down a hill in something they helped build.
Cut one 2-by-4 52 inches long for the mainframe.
Cut two 2-by-4s for the front and back axles.
Drill a 5/16-inch hole at the end of each axle. The holes should be 4 inches to 6 inches deep.
Drill a 5/16-inch hole at the back of each end of the front axle for the rope.
Measure 14 inches from either end of the front axle and drill a 3/8-inch hole in the centre of the axle.
Attach two 2-by-4 blocks to the axle. Each block should be 2-1/8 inch from the centre hole on either side of the hole. Use four No. 6-by-2-inch screws to attach each block.
Drill a 3/8-inch hole centred on the mainframe and 1-5/8 inch from the front.
Use 3/8-by-4-inch hex bolt, four 3/8-inch flat washers, and one 3/8-inch locknut to attach front axle to centre hole of mainframe. Tightness will need to be adjusted to allow for steering.
Align the back axle at a 90-degree angle to the mainframe and clamp in place. Drill two 5/16-inch holes through the axle and the mainframe. Attach the mainframe to the back axle using two 5/16-inch-by-4-inch carriage bolts, two 5/16-inch flat washers, two 5/16-inch split lock washers and two 5/16-inch nuts.
Cut out a 15-inch-by-20-inch square from the plywood for the seat bottom.
Cut out one 8¾-inch-by-20-inch square from the plywood for the seat back.
Cut one 2-by-4 12 to 14 inches in length for seat back support. Bevel this 2-by-4 by 10 degrees at each end.
Attach the back rest support to the mainframe and seat back using two No.8-by-3-inch screws.
Cut out two triangular-shaped pieces from the plywood, and attach them to the backrest support and the mainframe. Use wood glue and No. 6 1-1/2-inch wood screws.
Cut the 2-by-2 surveyor's stake to 14 to 16 inches at an angle and cover with the rubber from the old tire suing No.4-by-1-inch screws and No. 4 fender washers.
Drill a 3/8-inch hole through the handle close to the rubber end.
Drill a 5/16-inch hole in the mainframe where you are going to attach the brake.
Attach the brake to the mainframe using a 3/8-inch-by-4-inch lag screw and 3/8-inch flat washers on both sides of the handle.
Attach the seat belt with fasteners of your choice.
Attach the rope to the front axle.
Use 3/8-inch-by-6-inch lag screws and four 3/8-inch washers to attach the wheels.
Install the brake on the right front wheel for ease of use.
Use the seat belt and wear a helmet when operating the go-kart.