Kart Chassis Restoration
REVO acquired our Tony Kart Extreme 1999 go-kart frame in bad condition. The kart was most likely used before we obtained it as a fire extinguisher kart, which we extrapolated from the non-OEM add-on structural members and mounting tabs added. Due to the fact that this frame was made over 10 years ago, there were also some issues with hardware and parts.
The first step in restoring this chassis was assessing what needed replacing. We found that the entire brake system was very old and leaky, so we decided to buy a brand new Tony Kart BS2 brake system including a dual-bore master cylinder, braided steel brake lines, an OEM caliper, a self-ventilated brake disk, and a magnesium disk hub. The seat was also taken from an old car, so we purchased a KG Kalit bucket fiberglass racing seat. All the Nylock nuts were worn and had to be replaced as well. In order to check the professionalism of the chassis construction, we used aircraft stripper to remove the paint and brought the entire chassis down to bare metal. The GTAW welds appear to be extremely precise and professional, aside from the add-on members. Our subteam also used an angle grinder equipped with a cutting wheel to remove the added frame members. The rear axle bearings were well-worn, but one was almost completely seized, which also needed to be replaced. Future work needs to be done in remounting the seat, changing the tires, and remounting the brake caliper.