The Traditionally Cyclekart Design

So, you want to build a cyclekart and want to know where to start? Here is some information on rules and design of the cyclekart. 

Cyclekarting is a hobby that has been around for some time and has a few rules. Now let me state this again. First and foremost, cyclekarting is a hobby. Cyclekarting is supposed to be fun, an opportunity to build, learn, and grow from building your own “adult Go-kart”. There are many races around the country that follow a set of rules, set by a group of guys, many years ago. Yet, even those rules have been broken from time to time by people in cyclekarting groups in order to have fun with the cyclekart that they want. But what are the baseline rules that are accepted by most cyclekart groups and race events? Here is the baseline for Cyclekart GP:

• 38in width; outside to outside of wheel

• Honda Gx200 or clone

• CVT (Continuous Variable Torque converter)

• 17in Honda Cub 90 Wheels

• Must be built after an inspiration Pre-WW1 race car

• One Wheel Drive

• One Wheel Brake

That being said, I have seen 16in wheels, 19in wheels, I’ve seen cars that are 44in wide, and I know of engines that are built up specifically for racing. There are cyclekarts that have raced that are designed and built off of cars Post WW1. There are also cyclekarts that have raced that have no inspiration car but are solely built for the enjoyment of that style of car. 

Then what's with people being strict about following those rules, when within groups of events they allow bending of rules for some and not others? Why can one race with 19in motorcycle wheels, but not one that has 14in spare tire wheels? What is the rule on inspiration cars, when it is an inspiration, not a copy? I look at a pre WW1 car and find its key traits, and build on that. For example, if we look to draw a caricature of a face, does the person have a big nose, are they bald, or have a big smile? Then, I would use those key traits and make a drawing based on them. 

How to build a cyclekart:

• Step 1

  • Find your inspiration: There are many places to find cars to spark your inspiration; Google “1900’s Race Cars”, look on Pinterest, in old books, race events and their history. For the brave at heart you can join various Facebook Groups and see the photos posted. For me personally, I love the underdog teams.

• Step 2

  • Draw out your cyclekart: There are many ways about this; photocopy your inspiration car and draw on it, to scale a car, project an image of the car on the wall and draw the “cyclekart” shape on the wall, that allows you to fit easily and enjoy the drive. Or, do some drafting, on a board or program. Just get your body outline into the cyclekart to fit the pedals and steering wheel. There is nothing worse than building the cyclekart after someone else’s measurements just to find that you want more room here and less there. Be careful when following someone else's plans or drawings. Cyclekart sizes are like shoes, we can’t all share the same size. 

• Step 3

  • Parts: This can be one of the funnest parts or one of the most difficult that can keep you up at night. (I Know it keeps me up, thinking about where I’m going to get the right steering shaft). 

  • Where do I begin on parts? After your design, you will have an idea of what wheels you're going to use, the size of the steering wheel you will want, the basic idea and shape of the pedals, etc. Then, look for those parts on Marketplace, Craigslist, Yard Sales, anywhere. Most of the parts that Bonneville Garage uses are old Go-Kart Parts. I will provide a list of parts and links at the end of this document to help you find parts that are retail for those that are not hunters, scrappers, or fabricators, AND... There is nothing wrong with that!!!

• Step 4

  • Tools: I think the best part of starting any new hobby is the collection of new tools and the skills that come with using them. What are some tools you will need? Probably, the most needed tool in cyclekarting, other than hand tools, is a welder. There are many different welders out there and many, many, YouTube videos on how to use them. If I were to make a recommendation for those starting out, I would recommend Metal Inert Gas (MIG) welding. It's the most forgiving to new welders. There is also Flux Core Welding, which doesn't require a bottle of gas like MIG welding does. Flux Core is a bit more messy, with more sparks, but is a great alternative for the cost. The BIGGEST THING IS SAFETY!!! Have a fire extinguisher nearby and know how to use it. Have a safety plan in place for when you're working alone in the shop. 

• Step 5

  • Learn about the things you don’t know, from welding to metal shaping, or composite material shaping. Some of the best parts of this hobby is the chance to learn new skills and the chance to do it with your own hands. Why else would cyclekarting apply to you, but a chance to build something with your own hands and then the enjoyment to drive such a vehicle. From using design software, to learning about the math within the steering system, how hydraulic brakes can be improved, and the proper amount of gusset needed to prevent the frame from twisting too badly. 

• Step 6

  • Don’t give up! Much like any hobby, there is a learning curve that is needed to conquer and to have an understanding. There are many people within the cyclekart world, there are many points of view of what looks good and what doesn't. Listen, but understand that this is your project, and build the cyclekart that you want, not what other people see in your project. This fits perfectly into a Tall Tail that would be told around the campfire:  

“EVERYBODY’S CANOE” A young Indian was busy carving a canoe out of a log. As he worked, members of the tribe passed by. Everybody had a piece of advice to offer the young man. "I think you are making your canoe too wide," one of them said. The young brave, wishing to show respect for the advice of an elder, narrowed down the canoe. A little later, a warrior stopped by. "I'm afraid you are cutting the stern too full," he said. Again, the young brave listened to his elder and cut down the stern. Yet another adult stopped, watched a while, then said, "The bow is too sheer." The young brave accepted this advice as well and changed the line of the bow. Finally the canoe was complete and the young brave launched it. As soon as it hit the water, it capsized. Laboriously he hauled it back onto the beach. Then he found another log and started all over. Soon, a member of his tribe stopped by to offer some advice, but this time the young brave, was ready "See that canoe over there?" he asked, pointing to the useless craft on the beach. "That is everybody's canoe." Then he nodded at the work in progress. "This one," he said, "This is MY canoe!" 

So keep learning and building. This is a hobby of love and art, and to each, their own love of art will be shown within your work.

New Wider Cyclekart Design; 

"GT” simply means “Grand Touring” or “Gran Turismo.” In Italian, the term “Gran Turismo” refers to cars that can make long-distance “Grand Tours” in comfort and style. ... Also, GT models are typically larger and heavier than regular sports cars, and also emphasize comfort as well as performance.

Let's look at each of the suggested differences.  

1. Bigger. 

   1. All GT models Must be two seaters, a Grand Tour is no fun without someone to share it with. 

   2. All GT models should have a luggage capability that can fit a portmanteau of 20x16x2 (this would be luggage and/or tools and spare parts, as all repairs must be done there on the side of the road, minus any large failures that require welding or engine replacements). 

   3. Some form of bumpers both front and back. 

   4. With the requirement of 2 seats, the standard 38in track width is unrealistic, and with many of the roads we are taking to cross the country being ATV trails, we are going to set our limits based on that! A maximum width of 50in. Meaning you must be able to fit through a 50in opening, so that even the curb feelers must be within that 50in maximum size. 

   5. Height: The more I think about ground clearance, I feel there is no need to put a number on this. However, be aware that driving on ATV trails there will be ruts to clear. 

   6. Wheels: Being a bigger cyclekart class, let's talk about wheels. Many people say only wire wheels are permitted in Cyclekarting. I say phooey to that! If you use trailer wheels or spoked wheels to make it look right, go ahead. No hand truck tires and wheels are permitted, as they must be rated for highway use. As you get a wider tire it will require more space for the tire to turn. However, a 3in tire width is not the safest in wet conditions as we tour the country, and a 9in would be just too large for these karts. So go with a 3in to 5in tire width.

   7. 17in and up to 24in wheel diameter.

   8. Highway rated tires 

2. Heavier 

   1. This one just goes along with the “bigger”. If it is built to the specs listed above, it will result in a heavier Cyclekart.

   2. Will require front and rear hydraulic brakes.  

   3. Brakes must have an adjustable portioning valve 

   4. Parking Brake

   5. Full lighting system (headlight, turning indicator, running lights, brake lights, and cab lights).

   6. Horn, minimum of 38 dB

   7. Key start

   8. 5 gallon fuel tank

   9. Speedometer; GPS, or Cable, or GPS on your phone. 

   10. Proper exhaust system. 

3. Comfort

   1. Full suspension, springs rated for the weight of the cyclekart. We are traveling for 4000 miles, give your back and butt a helping hand by making sure that you are truly comfortable in the cyclekart GT.

   2. Proper seat upholstery 

   3. Would recommend a top, but not required. 

4. Performance 

   1. With the GT cyclekart being heavier and requiring two passenger seating, it is needed to be permitted to have a larger engine. Most GP cyclekarts use a 212cc and some mods are within that group that push those engines to 13hp if not more. Where will a GT cyclekart start at? The largest single cylinder engine listed is a BSA 654cc with a 70bhp. Thomas Knight of Las Vegas, had a great suggestion of 500cc. Still keeping them fun and enjoyable to all, but powerful enough to handle all the weight. With this being a world cyclekart class and people having different engines available to them, let's put a cap at 500cc for the GT cyclekarts.

   2. Transmission; with the ever load and cyclekart a CVT will not be the best choice. A motorcycle, ATV, or riding mower would be a better option for the drive train. An old 556 from a riding mower would be the best, giving you a three speed with a granny gear as well as a reverse gear too. The power input is on the side for easy alignment with the engine. It also has a built-in parking brake system.

That covers the 5 main points that make a Grand Touring different from a Grand Prix. These cars are designed for town to town racing. Will there be a large number of GT cyclekarts built or even a big following? I don't think so. This is to be more for the parades and enjoying getting the mail, than a GP cyclekart that you have to get shoehorned into. Will you get to race these at events? Most of them, no, because of the bigger size and engine. They are no less of a cyclekart than the GP models. These two different classes can co exist with each other for the enjoyment of all in the hobby.

For a refresher here is the specs for a Gran Turismo Cyclekart:

• Dimensions: 

  • Width 44in maximin 

  • Length no more than 130in

• Required accessories 

  • Functioning lights

  • Horn; 38dB minimal 

  • 5 gal fuel tank

  • Parking brake

  • Four wheel brakinging (with a adjustable proportioning valve) 

  • Exhaust system with spark arrestor

  • Key Start / Push button Start

  • Speedometer

  • Full Suspension

  • Proper seat upholstery 

• Drivetrain

  • Up to a 500cc engine

  • Can use any of the following transmissions (CVT would not be the best for a GT cyclekart): motorcycle, ATV, riding mower.  

Here is the baseline for Cyclekart Go:

• 42in width; outside to outside of wheel

• Honda Gx200 or clone

• CVT or Gearbox

• Go-kart/golf car tires

• Built after an inspiration vehicle Pre-WWII 

Student Built Cyclekarts:

You the Driver

• Full face helmet. 

• Neck Brace.

• Close-toed shoes.

• Long sleeved Shirt & Pants. Many use coveralls too

• Gloves

Your Cyclekart 

• Cyclekart MUST be visibly representative of an inspiration car from the period of the 1900’s to 1940’s.

• Cyclekart can not be wider than 44” from outside to outside of wheel

• Cyclekart can not be longer than 120” from tip to tip

• Cyclekart must use Spare tire wheels or trailer tires no wider that 4.5” tread and no tall than 22” tire 

  • (For national standardization of Cyclekart the traditional use of a wheel is a 17” Honda Cub 90 wheel. We are deviating from that requirement due to the safety of the student.)

• Cyclekart Engine: 230cc or less engine with a MOD 2 Defined by GoPower Sports: 

  • Air filter upgrade

  • Exhaust upgrade

  • Stock looking carburetor with larger jets and emission tube upgrades

  • 18lbs springs

  • Timing advance key

• Cyclekart must have a floor.

• We will “tech” all cyclekarts

• Have functional brakes. Will be test prior to the race

• Visible and accessible kill switch NOT on the engine within easy reach the of the driver

• Stock gas tanks that are solidly mounted. (no zip ties & tape).

• Must have chain guards, TAV covers in place.

• Seat must be lower than the tops of the tire

• Roll Bar with 3 point contact, with 2” between helmet and roll bar

• Roll bar must be minimum of 1-1⁄2” tubing .125 thickness

• A front or rear support at 30 Degrees from the upright

• With the cross support within 6in of the top of the hoop

• The loop and support must be attached to the frame via plates and with 4-grade 8 bolts