Flatworks plyfly, Assembly Manual

Page 1: ...For Ages 12 PlyFly Go Kart Instruction Guide 2015 Release HOW TO BUILD YOUR PLYFLY GO KART...

Page 2: ...kstarter campaign Your contribution is a great help and your support is much appreciated We hope you re as excited to get started on your new adventure as we are to be working on the FLATWORKS Enjoy y...

Page 3: ...s Brian Kaleida Matthew Keri Zee Jim K Brotman Dennis Cox Chris DePerro Family Woo Marcus Leef Tyra Hammett Nathan Pelsor Douglas Dayton Sam Bowling Lindsey Zimmerman Anthony Joshua Marcus Joe W Greg...

Page 4: ...ft 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 Assembl...

Page 5: ..._CH 1 August 7 2015 5 08 PM Introduction Each Plyfly Go Kart kit arrives in 3 boxes Review the contents of each box to ensure you have all the necessary parts to begin building your next adventure 1 1...

Page 6: ...g properly There are no areas of brake discs wheels chain or other moving elements rubbing on the wood That all shaft keys clutch sprocket brake disc wheels are installed and secured in place by a tig...

Page 7: ...ar The rider should wear at a minimum a full face DOT rated engine cycle helmet gloves and a helmet supporting neck brace These items and other safety equipment are not supplied with the kits but can...

Page 8: ...EEL 12 WHEELS LIVE AXLE 10 WHEELS LIVE AXLE 12 WHEELS 3 Plywood Sheet 3 4 depth 1 Plywood Sheet 1 4 depth 1 Flag 1 Drive Shaft Steel Keyed 5 8 D 18 L 18 L 18 L 33 L 36 L Box 2 contents 2 5 HP 4 0 HP 4...

Page 9: ...r connecting 35 Roller Chain 1 1 1 1 1 Control Cable 1 16 D throttle brake control cable 2 2 2 2 2 Red Throttle Cable Brake conduit 5 L 1 1 1 1 1 Green Throttle Cable Gas conduit 6 L 1 1 1 1 1 VXB Mou...

Page 10: ...2015 5 08 PM Introduction Preparing for a Plyfly Go Kart build you will need to cut out each structural wooden part from the plywood sheets The more time spent trimming tabs cleanly will save a lot of...

Page 11: ...t become spalled or rough from the cutting process using an orbital sander or sheet of sandpaper Reciprocating saw method INSTRUCTIONS 1 Select the correct blade for the cutting wood 2 Place the plywo...

Page 12: ...ev A_Seat August 7 2015 5 06 PM Introduction Before beginning this assembly be sure to chisel out and sand parts 22 33 These 12 components are required to fully assemble the go kart seat 8 3 Assembly...

Page 13: ...24 24 Sheet 3 3 4 Plywood Sheet Parts 22 23 Parts 25 27 22 23 25 27 26 Sheet 4 1 4 Plywood Sheet Parts 28 31 31 30 28 29 Recommended tools DESCRIPTION REFERENCE Dead blow hammer or mallet Electric dri...

Page 14: ...PLYWOOD SHEET 3 DESCRIPTION REFERENCE Part 28 Seat Bolster Left PLYWOOD SHEET 4 Part 29 Seat Bolster Right PLYWOOD SHEET 4 Part 30 Seat Thigh Bolster Left PLYWOOD SHEET 4 Part 31 Seat Thigh Bolster R...

Page 15: ...ons of parts 24 25 Note the location and orientation of the part 32 7 Secure part 32 to the seat frame using screws Use 8 screws Total of 8 locations 8 Using a mallet tap part 29 into seat frame Note...

Page 16: ...column A u g u s t 7 2 0 1 5 5 0 6 P M Introduction Before beginning this assembly be sure to chisel out and sand parts 19 20 These 3 components are required to fully assemble the steering shaft 12 4...

Page 17: ...DESCRIPTION REFERENCE Dead blow hammer or mallet Hammer Electric driver Required hardware DESCRIPTION REFERENCE 4 Small Metal Bushing Flanged 3 8 ID 1 4 L PN 12538 4 Spax Screw 8 1 1 2 L PN 12519 Req...

Page 18: ...re are 2 bushings 1 bushing per side 4 Hammer securely until the top of each bushing is flush 5 Using a mallet tap part 19 to part 20 Note The orientation of the parts 6 Secure the parts using screws...

Page 19: ...rack A u g u s t 5 2 0 1 5 1 0 3 8 P M Introduction Before beginning this assembly be sure to pre cut and sand parts 9 12 These 4 components are required to fully assemble the go kart steering rack 15...

Page 20: ...N REFERENCE Sheet 1 3 4 Plywood Sheet Parts 9 10 10 9 Sheet 2 3 4 Plywood Sheet Parts 11 12 12 11 Recommended tools DESCRIPTION REFERENCE Dead blow hammer or mallet Hammer Screwdriver Electric driver...

Page 21: ...embling the steering rack INSTRUCTIONS 1 Using a mallet tap parts 9 10 into the slots on part 11 Note the part orientation 2 Secure parts 9 10 using screws Use 1 screw per part Total of 2 locations 2...

Page 22: ...u g u s t 7 2 0 1 5 5 0 6 P M Introduction Before beginning this assembly be sure to pre cut and sand parts 13 18 These 6 components are required to fully assemble the go kart fixed steering column 18...

Page 23: ...Plywood Sheet Parts 13 13 Sheet 2 3 4 Plywood Sheet Parts 14 18 15 18 14 17 16 Recommended tools DESCRIPTION REFERENCE Dead blow hammer or mallet Hammer Required hardware DESCRIPTION REFERENCE 2 Smal...

Page 24: ...part 15 Note the orientation of part 18 2 Using a hammer tap the t ee nut until the top is flush with the wooden part 3 Using a mallet tap parts 15 16 17 18 into the corresponding slots on part 13 No...

Page 25: ...s t 7 2 0 1 5 5 0 6 P M Introduction Before beginning this assembly be sure to chisel out and sand parts 1 8 These 8 components are required to fully assemble 2 steering spindle Each assembly contains...

Page 26: ...t 2 3 4 Plywood Sheet Part 2 Part 5 2 5 Recommended tools DESCRIPTION REFERENCE Dead blow hammer or mallet Hammer Electric Driver Required hardware DESCRIPTION REFERENCE 2 Short Hex Bolt Grade 5 5 8 1...

Page 27: ...ndle Outer Spacer PLYWOOD SHEET 2 Part 3 Steering Spindle Inner Spacer PLYWOOD SHEET 1 Part 4 Steering Spindle Inner Spacer PLYWOOD SHEET 1 Part 5 Steering Spindle Bottom Left PLYWOOD SHEET 2 Part 6 S...

Page 28: ...parts 3 into the inner slot on part 5 6 Using a mallet tap parts 4 into the inner slot on part 6 Note the location of the bushings The bushing should face outwards Try to ensure 90 7 Using a mallet c...

Page 29: ...2015 5 06 PM 25 8 Pedal Assemblies Introduction Before beginning this assembly be sure to chisel out and sand parts 34 39 These 6 components are required to fully assemble the go kart gas and brake pe...

Page 30: ...Sheet Parts 34 Parts 36 39 34 38 39 37 36 Sheet 3 3 4 Plywood Sheet Parts 35 35 Recommended tools DESCRIPTION REFERENCE Dead blow hammer or mallet Hammer Electric Driver Required hardware DESCRIPTION...

Page 31: ...art 38 Part 39 Note the part orientation The final 2 assemblies are mirror images of each other 2 Using a mallet tap parts 36 37 into the slots on part 34 Note part location and orientation of parts 3...

Page 32: ...rame August 7 2015 5 0 6 PM Introduction Before beginning this assembly be sure to chisel out and sand parts 40 55 These 11 components and assemblies1 3 are required to fully assemble the go kart fram...

Page 33: ...4 Plywood Sheet Parts 40 43 Part 49 49 41 40 43 42 Sheet 2 3 4 Plywood Sheet Parts 44 46 Part 48 Part 52 45 44 46 52 48 DESCRIPTION REFERENCE Sheet 4 1 4 Plywood Sheet Part 47 Part 50 50 47 Sheet 4 1...

Page 34: ...5 SINGLE WHEEL KIT PN 12504 4 LIVE AXLE KIT PN 12504 10 Large Tee Nut Zinc Plated 3 8 16 PN 12545 10 Small Tee Nut Zinc Plated 5 16 18 PN 12510 30 Spax Screw 8 1 1 2 L PN 12519 3 VXB Mounted Bearing 5...

Page 35: ...ght PLYWOOD SHEET 1 Part 44 Front end Bottom PLYWOOD SHEET 2 Part 45 Front end Top PLYWOOD SHEET 2 Part 46 Frame Rail Bracket PLYWOOD SHEET 2 Part 47 Sprocket Guard PLYWOOD SHEET 3 DESCRIPTION REFEREN...

Page 36: ...nuts on part 49 Note the location of 4 small tee nuts on part 50 5 Press the large tee nuts into Part 42 43 Part 47 Part 50 on the opposite side of the small tee nut installation Note the location of...

Page 37: ...e Slide Drawer Kit Use 4 screws Total 4 locations 15 Test the drawer slide fit by moving the slide back and forth Be sure there are no interferences between any screw head and the slide 16 Extend the...

Page 38: ...ws Total of 12 locations 24 Flip the assembly over and using a mallet tap any unseated tabs into place It is best to do this with 2 hanging off the edge of a table or saw horses 25 Secure part 44 to t...

Page 39: ...t and right side faces Use 12 screws Total of 12 locations 32 Using a mallet tap part 52 into place Note the orientation and position of part 52 33 Secure part 52 using screws Use 2 screws Total of 2...

Page 40: ...assembly right side up 41 Lay part 50 with the small tee nuts facing upwards into place Note the orientation and position of tee nut pattern on part 50 42 Secure part 50 to the assembly using washers...

Page 41: ...ore beginning this final assembly be sure to have assemblies 1 7 completed These 8 assemblies are required to fully assemble the go kart This chapter contains 10 individual procedural parts to success...

Page 42: ...L LIVE AXLE KIT 10 WHEELS PN 12581 1 Drive Shaft Steel Keyed 5 8 D 36 L LIVE AXLE KIT 12 WHEELS PN 12582 1 Brake Disc PN 12532 1 Brake Disc Hub PN 12533 1 Long Hex Bolt Axle Grade 5 5 8 11 11 L SINGL...

Page 43: ...nduit 5 L PN 12527 1 Green Throttle Cable Gas conduit 6 L PN 12528 Overview of the required hardware DESCRIPTION REFERENCE 6 Zip Tie 10lb Nylon White 7 8 D 4 L PN 12558 PART 7 1 Gas Powered Engine 2 5...

Page 44: ...Nut 5 8 11 PN 12506 1 Rear driven wheel 10 D SINGLE WHEEL KIT PN 12590 3 Undriven wheel 10 D SINGLE WHEEL KIT PN 12591 2 Rear driven wheel 10 D LIVE AXLE KIT PN 12590 Overview of the required hardware...

Page 45: ...OD SHEET 4 Part 54 Fairing Right PLYWOOD SHEET 4 Part 55 Fairing Front PLYWOOD SHEET 4 Overview of the required assemblies DESCRIPTION REFERENCE 2 Fixed steering column Assembly PARTS 13 18 3 Steering...

Page 46: ...N 12581 1 Drive Shaft Steel Keyed 5 8 D 36 L LIVE AXLE KIT 12 WHEELS PN 12582 1 Brake Disc PN 12532 1 Brake Disc Hub PN 12533 1 Long Hex Bolt Axle Grade 5 5 8 11 11 L SINGLE WHEEL KIT PN 12502 4 Butto...

Page 47: ...y sliding it through the outer mounted bearing located on part 43 only If there is too much resistance to insert the drive shaft temporarily loosen the mounting screws so the mounted bearing is loose...

Page 48: ...ially be installed and then adjusted INSTRUCTIONS 1 Insert the socket head cap screws with an oversized flat washer through the holes located on part 43 Use 1 socket head cap screw with 1 oversized fl...

Page 49: ...mn Assembly PARTS 19 21 Part 3 Install the steering column assembly INSTRUCTIONS 1 Position 3 so that the gear aligns with those on 1 Be sure the gear alignment marks located on parts 20 12 line up No...

Page 50: ...facing out Check that the bushings on 7 are completely seated before installing Note the location and orientation of the assemblies 3 Align the gear teeth of 7 with the gear alignment mark located on...

Page 51: ...d by these holes The holes should be pointing towards the middle of the fixed steering column Note the right and left pedals tabs holes and their position in the Assembly 2 Position 5 on the right of...

Page 52: ...ble 1 16 D throttle brake control cable PN 12525 1 Red Throttle Cable Brake conduit 5 L PN 12527 1 Green Throttle Cable Gas conduit 6 L PN 12528 6 Zip Tie 10lb Nylon White 7 8 D 4 L PN 12558 Reference...

Page 53: ...then through the hole located on the left side of part 17 Note the location and direction of the red cable Be sure to seat the red cable in the notches located on part 19 of 3 4 Continue to run the re...

Page 54: ...ess cable tie material 9 Feed the brake control cable through the hole located in the 6 and into the red cable Note path of the brake control cable through the brake pedal 10 Fish the brake control ca...

Page 55: ...ngine 4 0 HP MODEL Box 2 1 Clutch 35 Chain 11 Tooth Pulley for 5 8 D 2 5 HP MODEL PN 12576 1 Clutch 35 Chain 12 Tooth Pulley for 3 4 D 4 0 HP MODEL PN 12577 1 Roller Chain 35 Chain 29 5 8 L PN 12524 1...

Page 56: ...et Screw Clutch PN 12563 1 Pan head M6 12 mm L 4 0 HP MODEL PN 12564 Part 7 Install the engine and drive train The engine arrives with no oil no configuration is required INSTRUCTION 1 Stand the engin...

Page 57: ...pliers stretch the extension spring and hook it through the second hole on the opposite side of the throttle linkage Note the location of the extension spring 8 Slide part 56 into the space located on...

Page 58: ...n the clutch sprocket with the drive shaft sprocket vertically 15 Connect the chain by sliding the posts of the master link into the holes located at the ends of the chain Note the order of the assemb...

Page 59: ...tion instruction continue to step 32 25 Thread the green cable into the right side of the engine Note the location of the green cable 26 Secure the green cable loosely in the clamp Note the location o...

Page 60: ...ay through to 5 Note the location of the throttle control cable 33 Secure the throttle control cable using the throttle cable clamp at the bottom of 5 Be sure the control cable is taut before tighteni...

Page 61: ...riven wheels using lock nuts Hint To keep the wheels from rotating place a large slotted screwdriver into the heads of the front axle bolts 6 Slide the shaft collar over drive shaft SINGLE WHEEL KIT c...

Page 62: ...head screws into the parts 41 42 located on 9 Note the location of the Fillister head screws 2 Secure the Fillister head screws to be flush with the wooden surface of part 41 3 Position 4 at the forwa...

Page 63: ...steps 1 through 3 on the opposite side using part 54 5 Thread the green elastic cord from the top through left hole located in part 16 of 2 Note the part 16 6 Tie an overhand knot on the bottom side...

Page 64: ...150718 PLYFLY rev A_EM August 7 2015 5 06 PM 60 11 Master List...

Page 65: ...Parts 52 Visual reference of the plywood sheets DESCRIPTION REFERENCE Sheet 3 3 4 Plywood Sheet 22 23 25 27 26 35 50 47 Parts 22 23 Parts 25 27 Parts 35 Part 47 Parts 50 Sheet 4 1 4 Plywood Sheet 31 3...

Page 66: ...eering Spindle Bottom Right PLYWOOD SHEET 1 Part 7 Steering Spindle Top PLYWOOD SHEET 1 Part 8 Steering Spindle Top PLYWOOD SHEET 1 List of the wooden parts DESCRIPTION reference image Part 9 Steering...

Page 67: ...OOD SHEET 3 Part 23 Seat Side Right gas tank side PLYWOOD SHEET 3 Part 24 Seat Crossbar PLYWOOD SHEET 1 List of the wooden parts DESCRIPTION reference image Part 25 Seat Crossbar PLYWOOD SHEET 3 Part...

Page 68: ...SHEET 1 Part 39 Pedal Side PLYWOOD SHEET 1 Part 40 Frame Rail Inner Left PLYWOOD SHEET 1 List of the wooden parts DESCRIPTION reference image Part 41 Frame Rail Inner Right PLYWOOD SHEET 1 Part 42 Fr...

Page 69: ...ail Engine Mount PLYWOOD SHEET 1 Part 50 Engine Mounting Plate PLYWOOD SHEET 3 Part 51 Floor Panel PLYWOOD SHEET 4 Part 52 Frame Gusset PLYWOOD SHEET 2 Part 53 Fairing Left PLYWOOD SHEET 4 Part 54 Fai...

Page 70: ...ies DESCRIPTION REFERENCE 6 Brake Pedal Assembly Parts 35 38 39 7 Left Spindle Assembly Parts 1 3 5 7 8 Right Spindle Assembly Parts 2 4 6 8 9 Frame Assembly Parts 21 28 Note If you received a 1 4 ply...

Page 71: ...er Orbital Sander optional Jigsaw or Reciprocating Saw optional Electric Driver Impact Driver optional List of the tools needed DESCRIPTION REFERENCE IMAGE Screwdriver Allen Wrench or ratcheting allen...

Page 72: ...34 Master Chain Link 35 Roller Chain connector 1 1 1 1 1 12005 Part 56 Clutch Guard Side Engine Mounting Plate 1 1 1 1 1 12006 Part 57 Clutch Guard Top Top Cover 1 1 1 1 1 12007 Part 58 Clutch Guard C...

Page 73: ...12581 Drive Shaft Steel Keyed 5 8 D 33 L LIVE AXLE KIT 10 WHEELS 1 12582 Drive Shaft Steel Keyed 5 8 D 36 L LIVE AXLE KIT 12 WHEELS 1 12508 Drawer Slide Hardware included 10 L 1 1 1 1 1 12517 Green El...

Page 74: ...Short Shoulder Screw 5 16 18 3 8 D 1 00 L 1 1 1 1 1 12514 Long Shoulder Screw 5 16 18 3 8 D 2 25 L 1 1 1 1 1 12515 Button Socket Head Cap Screw Zinc Plated Steel M8 12mm L 5 5 5 5 5 12516 Flat Washer...

Page 75: ...55mm L 2 2 2 2 2 12551 Sheetmetal Screw Galvanized 6 8 8 8 8 8 12553 Fillister Head Screw 5 16 18 3 4 L 2 2 2 2 2 12558 Zip Tie 10lb Nylon White 7 8 D 4 L 6 6 6 6 6 12559 Button Socket Head Cap Screw...

Page 76: ...150718 PLYFLY rev A_Legal August 5 2015 10 3 8 PM 72 12 Legal...

Page 77: ...ted to my participation in this activity including but not limited to any and all damage to or loss of my property or the property of others personal injuries to me or others of any type including dis...

Page 78: ...150718 PLYFLY rev A_Terms Conditions A u g u s t 5 2 0 1 5 1 0 3 8 P M 74 13 Terms Conditions...

Page 79: ...in whole or in part by equipment malfunction from whatever cause or any other negligence or fault of Flatworks 5 Indemnification In the event that User or anyone acting on his or her behalf brings a c...