1 5 0 7 1 8 P LY F LY r e v A _ T O C | August 7, 2015 5:06 PM
IV
What's Inside?
1 Exploring the kit 1
Warnings and safety 2
Handling and storage 2
Why Wood? 3
Good to know 3
What’s in the kit? 3
Unpacking the boxes 4
2 Getting Started 6
Getting started 7
Recommended tools 7
Chisel & hammer method 7
Reciprocating saw method 7
3 Seat Assembly 8
Plywood sheet reference 9
Recommended tools 9
Required hardware 9
Required wooden parts 10
Assembling the seat 11
4 Steering Column Assembly 12
Plywood sheet reference 13
Recommended tools 13
Required hardware 13
Required wooden parts 13
Assembling the steering shaft 14
5 Steering Rack Assembly 15
Plywood sheet reference 16
Recommended tools 16
Required hardware 16
Required wooden parts 17
Assembling the steering rack 17
6 Fixed Steering Column Assembly 18
Plywood sheet reference 19
Recommended tools 19
Required hardware 19
Required wooden parts 20
Assembling the steering column 20
7 Steering Spindle Assemblies 21
Plywood sheet reference 22
Recommended tools 22
Required hardware 22
Required wooden parts 23
Assembling the left & right steering spindles 24
8 Pedal Assemblies 25
Plywood sheet reference 26
Recommended tools 26
Required hardware 26
Required wooden parts 27
Assembling the gas & the brake pedals 27
9 Frame Assembly 28
Plywood sheet reference 29
Recommended tools 30
Required hardware 30
Required assemblies 30
Required wooden parts 31
Assembling the frame 32
10 Putting the go‑kart together 37
Overview of the recommended tools 38
Overview of the required hardware 38
Overview of the required but not provided 41
Overview of the required wooden parts 41
Overview of the required assemblies 41
Part 1 Install the rear axle 43
Part 2 Install the brake caliper 44
Part 3 Install the steering column assembly 45
Part 4 Install the steering spindles 46
Part 5 Install the gas & brake pedals 47
Part 6 Install the gas & brake cables 49
Part 7 Install the engine and drive train 52
Part 8 Install the wheel assemblies 57
Part 9 Install the seat assembly 58
Part 10 Install the fairings 59
11 Master List 60
Visual reference of the plywood sheets 61
List of the wooden parts 62
List of the wooden assemblies 66
List of the tools needed 67
List of loose contents 68
List of the packaged contents 70
12 Legal 72
Legal 73
13 Terms & Conditions 74
Terms & Conditions of Purchase and Use 75
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