How to build an IRS Chain Drive Spool: Affordable Easy and NO LATHE!
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- Опубліковано 19 січ 2023
- Check Description for links to plans, detailed build series, FaceBook build group and more!
A year of development has led to this; A super strong Center Carrier for any IRS application without the need for a lathe. Built from readily available off the shelf parts along with accurate laser cut parts so you can assemble yourself for a fraction of the cost. This is what you have been looking for! I know this because as a builder I've been trying to find this for almost 20 years. Plans below show the required parts with part numbers for a complete IRS setup for 420 or 520/530 chains, .dxf files to upload for laser cutting, measurements for all parts, every single nut and bolt needed for assembly and plenty of pictures and walkthroughs. This setup is appx 56" hub face to hub face and has proven 15" or more of travel without binding. This has been missing for the home fabricators for too long. Enjoy!
-Kyle
Plans available here:
kj-raycing.dpdcart.com
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Custom length chassis
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Preferred tubing bender and notcher
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DISCLAIMER
Videos are for entertainment only, work performed in the video should only be accomplished by a professional technician. KJ Raycing will not be held liable for ANY personal injuries. - Розваги
I’m not even done watching the video yet and I already give you more respect than anyone out there. You are doing what most of us wish some builders would do. Taking the time to go step by step not only with the list but actually showing us what to do. There’s literally no way to mess this up!!! I’m subscribing!! Me and my dad have been looking for something to build together that won’t break the bank. This is right up our alley.
Man this is the stuff that keeps me going, thank you so much! I’ve wanted a walkthrough video series like this for a very long time. No one did it so I took a shot at it and I’m glad so many people are joining in on this awesome experience. There’s nothing like taking a pile of metal and making into your own dream machine. I wish you and your dad the best and I know you will have a successful build!
-Kyle
*This channel is so slept on*
Wow...I am absolutely in awe of your cross cart tutorial...for a while now I have been looking for a hobby that I can get my teeth into for my grandchildren where I can sit on the porch with my wife and watch our grandchildren tear up our 22 hectare farm 😂 respect to you Sir for your great tutorials 😊
Exactly. My friend mentioned cross cart. I looked it up and I was like yeah I'm hooked. I need to build everything I need just so I can build this cross kart
This is the first time ever "Commenting" on a video but I had to! I'm a busy guy also with a family, business, etc. and just wanna say you are EXTREMELY generous for the time you have taken to offer your help and instruction to others! I was planning a cross kart build with my kid and was researching tubing benders recently and found Rouge Fab (great guy's!), then saw your videos on their site. I immediately switched gears and have been watching your videos every chance I get for the past few days. Looking forward to this process and thanks to you it should be a much smoother one! Keep it up man and thank you for all the hard work and help!! Much respect!
Thank you so much! This was all created at the request of guys building so this comment means a lot. The budget series is a little easier to watch because I figured out editing a little better and you still get the same great chassis. Thank you again, enjoy your build with your kid 😁
I just bought the plans, it took half a reem of paper to print out. The plans for everything was $100. With the amount of engineering that went into this, and all the videos for support, this was a hell of a deal! I have 2 2007 Polaris Outlaws for donor quads, I am really looking forward to this build!!!
Nice job. You are a natural teacher. Never discount a good eyeball. Or a good cheap engine. Getting the degree of accuracy you got is a lot of work.
Thank you so much. I do rely on the old 20’ look at it 🤓
I see other applications this could be modified to adapt to. Outstanding!!!
Are you doing a hell of a job and watching you for a couple years and there’s never enough time so I’m with you on that!
i think your idea is one of the cheapest and best way of making a IRS chain drive spool THANK YOU FOR SHARING. LOVE THE CONTENT!!!!!
Thank you so much!
Thank you for your time and knowledge.
I typically fabricate pieces needed for my projects so I appreciate the effort you have obviously invested.
You are a superhero for humanity. Thank you for your CARE
Building a Next Generation Cyclekar - passing the Cyclekart group for more fun. Video 1 & Video 2 the bomb
Thanks for the most informative video ever!! I started building trikes a few years back amd asking questions I ran into so many dead ends no one wanted to share information.. I've built a few but this is definitely amazing can't wait to put one of these on my build
I am actually still working on this as it going to help a lot of guys. More mods means more versatility and lower costs. One of these on a drift trike would be sick! I hope I get to see it 👍
I'll definitely be buying your plans. You did a great job explaining everything i think i can handle this project
Awesome man! Thank you so much 👍
Love what you're doing with this! It's great and I'm looking into doing s build this spring/summer
Bro, I have so much respect for you. Thank you for all your videos!!!!
Aw man thank you so much! I really appreciate that!
This is awesome! I could never figure out how to build one of these. Thank you for this!
It took a long time with lots of trial and error and lots of $$$. But since I have a career (not youtube), all of the money from the channel and plans goes towards stuff like this. Thank you so much 👍
I have to admit I'm jealous you came up with this before me. But more importantly. That website where I can get stuff made easily. Instead of days of cutting and grinding to make my stuff. Is the best thing posted to UA-cam.
Yeah it really unlocked everything once I found them. So glad to share with you and thank you for the kind words 👍
I love you !!!! Man.....Thank you so much for allowing the simple man a chance @ having some real big boy toys!!!!
Thank you, you're definitely going to heavan...you're awesome!!!
What an awesome compliment!!! Thank you so much! There are so many guys making their own machines which is a huge compliment, but this is really cool. Thank you!
Brother you got a new subscriber here and a new customer too thank you my friend and keep on building 👏🏼👏🏼🙏🏼
Thank you so much!
Thank you so much for this! I want to make so much stuff and don't know how to get parts made so that I can build what I want. I have no experience with any of this. But, I can certainly learn and am extremely excited to learn more from you. I echo what KontraK Gaming said, wholeheartedly! New female fan here. lol
May u live forever
Thanks bro your varry informative thats a damn good setup keep doing what you're doing and i wish you and your family peace happiness and safty thanks bro
You sir deserve a clap from a British engineer 👏👌👍🏴 good work keep it up I was just curious but great watch.
Thank you very much!
I really appreciate the great info. I used to teach freshman chemistry labs and I'd say the same thing there, safety glasses don't help if they aren't in place. I understand I work in a non heated/cooled shop and they can be annoying at times. That being said I had to get a contact removed from my eye once at the eye doctor and between the two, it is a lot less annoying to clean off your safety glasses every once in a while then to have someone try to get something out of your eye. Not to mention the time you have to waste going to the doctor and walking around with a big patch over your eye. So not knocking you just throwing out a friendly reminder to keep those eyes covered.
I cannot even.. so much value and yes, it’s very cool
Thank you so much!
Well that settles it... I've got to get my shop in order and a few more tools.
So good, glad I found your channel.
This is the best video ever I need to order 1
Very well thought out for the DIY guys.
Thank you very much, it was a year in development for all of us diy guys. 👍
your work is just amazing
Thank you! Cheers!
This channel is so cool! Hey a tool that might be a game changer for you. Build a 2x72” belt grinder. Common in the knife making groups and easy to find plans for. You can easily change small roller attachments to touch up tube notches or tabs and things like that. Such a good added fab tool. Cheap and easy to build.
Thanks, man. There are all kinds of tools I want for sure, but I try to keep it to just using simple common tools outside of the bender and notcher because that's how I started. Thank you for the heads up though, I will definitely keep this in mind.
One of the best vids I have watched so far, when I get ready to do my kart your channel is where I’m deff coming back to…A+ for one of the best tutorials I have seen yet, and you just gained a subscriber with all notifications..
thank you for your explain idea and load power ect.
Dude, you are the man! 👍
Great Video!
That's awesome dude ! Bought a "spare" Honda CB600 hornet for the rear shock and forks for my road bike and now I just might have another use for the engine 😉
Absolutely! So much fun with all of that rev range!
Just purchased the plan. So excited to get started. Of course there are no splined shafts anywhere to be found. I better buy 3 when they become avail.
Oh I know, this came up on the FB group like a week after the video and a manufacturer that was in the group spoke up and now everyone is getting their rear ends built. Ptlracing.com or the main suppliers should have them back in stock soon.
I’ve pondered this type of setup for so many hours in my mind. Really cool to see it done. I’d love to build a very light, super simple single seat long travel using a modded 212 with a 40 series torque converter. Something like that is more feasible for the average person like myself. What you build is really top notch and super cool but also difficult. Lol I sweating watching all those jigs and bends and notches! I’m subscribing and will enjoy the knowledge you share👍
The hardest part is to start. There have been so many first time fabricators have success building these. The jigs are simple and the bends and notches have their own custom instructions. Don’t think of it as a whole or it will seem very difficult. Start with just doing one bend and the rest will come. I wish you the best 👍
Seriously impressive
Thank you so much
Beautiful! even the explanation
Oh yeah. I enjoyed your videos.
Amazing sir I want to be like you 🙌🏻🙌🏻
You do great work....Fun stuff.
Thanks man! I appreciate that.
Just purchased the plans tonight. Can’t wait to get everything together.
Just had ACL reconstruction courtesy of Uncle Sam, so it might be a slow process.
Heal up quickly and thank you for joining in on the fun 🦾
I know this is an amazing setup (because it looks like mine) but even better!!
I like your setup too, I just had a look at it, you just gotta work on the wheel side of things 😁. Can’t wait to see more of your videos.
@@KJRaycing Thanks! I just started but allready have planned some crazy content!
congratulations you are an exceptional inventor and you deserve more subscribers for what you do compared to others who have more subscribers but only do useless stupid things!!!
Very good
Very nice.
Great build. I'm thinking about a rear-end for my electric glide..
ya'll will never stop
yeah im buying a tubing bender with my tax refund then im buying your prints. youre the man dude thanks you
Man I wish I could help everyone get started on their builds. This stuff is so incredibly fun. I can’t wait to see what you come up with for your build 🦾
Fantastic. I think I'm only 1 project away from starting my kart, next year I bet. :)
Go for it! I can’t wait to see it, I love all the builds.
Yeah just do it! I started building with a very rough plan in mind and it did work out amazing! I learned a lot from a lot of UA-camrs!
THANK YOU 🤘
Put your center section in the freezer for a couple hours. Bearings literally fall in. Your designs pretty good. Video is good too.
Sounds like you are ready to put a Homebrew carrier together 👍
I did almost this exact differential 2 years ago and its holding up fine to 110hp sportbike engine powering it.
Very cool!
@KJ Raycing I sent you pics on fb back then. Not sure if you remember but also a video of my buddy drifting it.
Ok i see its in part 2
thank U very much merci et bravo 👏 👏
Thank you so much!
I have a 500 2 cycle I would like to put in one of these.
Great great stuff kudos I’d subscribe to your channel for more educational inventions thanks
Thank you! I appreciate it.
So cool!Which is engin?
I want to build the smoothest riding golf cart possible.
It will be electric. 35hp electric motor.
Maybe even 4wd.
Long travel independent suspension all around.
Will your kit adjust to be more golf cart like as far as enter and exit.
Any ideas for frame and suspension?
Ever looked into the legend cars and how they use an adapter?
Can you recommend a channel that can show me how to convert a peddle start motor to either a pull start or electric start
Nice video , I have been following the build all the way. Wouldn't s shaft driven be more better and faster.
There are benefits to both for sure. I prefer a chain so I can swap gearing for offroad tires, street tires and trail/track setups.
Im building an Awd v8 reverse trike. I need 2 sprockets for the chain. Im going to use 530 chain. Can they make steel sprockets that can handle the power?
This diff doesn't use rear diff spur gear? So both wheel will traving same rotational speed cornering?
What is the diameter on the splined shaft? I have some and want to know if I can use what I have? Thanks for the info.
WOW! I am very impressed with your work and build of the cross kart. I would like to know what wheels and tires you used in this video?
Thank you so much! All the components used are in the components list 👍
For reverse cut the ring gear into the brake rotor and then mount the starter high
You make it sound easy 😁, I wish it were that easy. I’ll definitely look into though, thank you.
Have scs cut the brake rotor with the gear tooth on it then you can use the caliper mount to bolt the starter in line with the top of the rotor at least that was my idea to simplify it for ease of assembly and room though it might help a little bit thanks for listening
Hello! Do you make the plans in metric as well?
I have a question regarding solid rear axle versus what you built known as a spool to me. I have a yard card yerfdog a small 10 horsepower go cart that has a lot of scrub because of the solid rear axle .Do you get the same amount of scrub from a spool and IRS as opposed to a solid rear axle. Thank for the brain power you shared with the buggy community. I raced high end rc cars for years and always wanted to build my own buggy sized spider diff. That way I could get slip differential.
A solid rear axle has zero scrub that I’m aware of. There are a lot of factors with scrub and they are probably really important to well funded and highly competitive race teams. There are guys that look at my builds and think that they are missing all the fancy expensive one-off race equipment… well you see how they drive with the simple methods I use, which was the whole idea. They don’t need diffs, my daughter pushes it around turning and everything and she’s 9… in short if you get your mind wrapped up in the complicated stuff you will never finish one. Keep it as simple as you can 👍
is there anyway i can buy a prebuilt one?
i dont have the time to build one.
That is an awesome axle Carrier great job dumb love the part but you don't have to have a mill
That was the whole idea. Lathes are awesome but us normal dudes don’t get to have them 😁. Thank you.
Do you think this would withstand a hayabusa build? If not, what would be the changes you would make?
Well I think we are going to find out pretty soon. I’m pretty confident 🦾
A typical sport bike could have a combined primary drive ratio and 1st gear ratio of over 4:1. That being the case, a small engine with 50 lb/ft of torque could exceed the rated torque of the PTO shaft.
These are shafts used on tractors with more than 50 lb/ft of torque and reduction gears on top of that… you pointed out a possible problem but you did not present any solutions.
MIG, TIG, or Stick should be fine to weld those on. TIG looks pretty but isn't any stronger than the other techniques.
How wide with the mita axles hub to hub
Need to do a chain driven differential. I been messing with it for a while
No need for a diff on a go kart…
But there is in asphalt applications…
I just took it to an asphalt track with no diff. A diff would not have changed anything, but what do I know 😁. I hope you figure out what you need to 👍
It’s a really stout setup but is it serviceable? I didn’t hear you mention that you need to weld both sides of the cv flange, but I imagine you’d need to looking at how both sides are identical
It is semi serviceable. This should last a long time and you would only need to replace less than half of the parts if more than one bearing ever goes. There is a part two and three to show full completion and an upcoming part 4 for ultra high power setups.
You reference the polaris break caliper. Are the laser cut parts designed strictly for this caliper? Can I use Yamaha calipers?
The laser cut parts are only for this caliper. They are readily available, inexpensive and as a two piston setup they have plenty of stopping power 😁
@@KJRaycing perfect. I'm glad I asked before I pulled the trigger on a purchase. Thank you
All of the part numbers are in the plans 👍
I did purchase these plans for the IRS chain drive spool but having a problem sourcing the Splined axle at G7G not sure what the part number is but got no results. Think you can help me out with the axle ? Need more information.
Thanks
Thank you for emailing me and I’m glad we got it figured out.
Side note. I spent years doing demolition derby. 1/4 inch is fine. A general rule of thumb. If it should safely bend? 3/16 inch steel. If it shouldn't bend? 1/4 inch steel. That came from hundreds of crashes.
I’m finding more and more that if things are designed well they don’t need to be a giant mass of metal to make up for it. You probably won’t like this, but I use 1/8” thick bar for the suspension and shock mounts… over three years of driving them everywhere and nothing broken. I am using 3/16 on the two seater though. Thanks for the comment and I look forward to more from you, you seem to be a very fun and experienced driver 😎
@@KJRaycing 1/8 is perfect. It's how you use it. I only go up to 3/16 DOM. On full size heavy offroad cars.
i was wondering if this plan would work with coilovers instead of off road use i would like to build somehting like this for drifting but i dont really no what to do i just now i want all suspension
Yes. The chassis is designed for however you want to use it. I run mine with two modes; low and aggressive and different shock positions for off road with lots of clearance. I have two separate sets of tires too because that’s less expensive than having two karts 😁. Build it to how you want to drive. I’ll be tuning my 100hp kart for an asphalt race track even in June.
Do you ever have issues with the splined axle spinning faster than the bearings?
I’ve had zero issues after 100’s of hours with it; but there is a locktite you can use to make sure it won’t spin inside the bearings if you are worried about it. I was told about this by a builder, man I love this community!
Can I utilize less bearings, and cut the shaft shorter and make a narrower version? Or Shaft too difficult to cut? Low HP application.
Since they are plans they can be modified however you want to do it. I built it the way I did for bolt clearances, longevity and ease of assembly.
@@KJRaycing Thank you, i'm just thinking if I want to use miata axles it's for a smaller kids machine that I'm still trying to maximize travel on, yet want it slightly narrower if I can. 200cc 2 stroke with a cvt, shouldn't require something as robust as your original.
Narrow and long travel doesn’t go well together. My 9 year old drives my budget kart all of the time, it’s pretty much hers. I just made the driver compartment of a full size able to fit her and adults well. Check the channel for the driver adjustment video, it may change the way you think about a kids kart…
@@KJRaycing thanks I'll watch it.
Would it be able to handke 180hp from an r1 or would the jd garage spool be better
A hardened 21 spline shaft will always handle more than a keyed shaft. But I think either would work for you.
So in the plans for the vf-1 would this irs be in there or would I have to purchase separate blueprints for the irs?!?
I didn’t want to make someone that wanted to use the rear in their yerf dog or custom build have to buy the VF-1 plans to get them. If you’re pinching pennies on getting the plans you are going to have a very rough build. Plans for the rear end saves you money, time and frustration over the other options for a chain driven spool; I hope that’s worth the very small fee.
I love your build man you did a great job, and thought about every single thing, I haven’t seen another build like yours as supper complete,detail by detail, I was just wondering if get the blue prints did I also have to buy the blueprints for the irs separate, I mean it was to buy all together not just half. Thanks a lot for for answering my questions!!!
Oh I got ya. 👍 And thank you so much, that is a huge compliment and I worked very hard just for you guys to feel that way. I worked on putting together build packages but it just got confusing, So I just left it straight forward. Thank you again and welcome to the crosskart movement 🦾😎
I Really do respect your work sr, I know it’s not easy to be braking your head and building all this parts just for free. Thanks for your all your work.
Thank you so much, I really appreciate that.
So this is an open diff set up. Have you made a limited slip diff set up?
This is not an open diff. It is a live axle irs setup. The wheelbase is too short to need a diff.
Got the plans today and downloaded them but only the make two .DXF file will transfer to sendcutsend. All the others just put garbage on the screen. I get errors when I try extracting the zip file
Nice! Close all other programs before extracting/unzipping.
I keep trying to order your plans through link and it keeps going wrong I'm trying to get the V the VF and we're absolutely assembly and the parts lists
Paypal always works, the security stuff on the credit cards is pretty intense. Thank you in advance!!! 👍
Where do you buy the axle the tractor pto thing
It’s in the plans, kj-raycing.dpdcart.com
Are these prices American or Canadian dollar?
They would be american dollars, but With steel prices fluctuating like they are it could represent just about any currency!
Can this design be used for a trike?
It can be used to drive two wheels using a chain, I leave the rest to you 👍
Hello again. I am sending the dxf files over to the local laser cutter. He is requesting the pdf files for the parts as well. Do you happen to have those?
Who is the laser cutter?
The plans are copyrighted so please only give the laser cutters the dxf files.
would you sell one of these that you already built and put together?
Not for what anyone wants to pay unfortunately. I have sold kits in the past with everything you need (drilled, tapped, bearings pressed, all hardware) but I won’t do the welding for you as I am not certified.
do you sell those all ready done ?
I make batches from time to time for the plan holders in the Facebook group. I’m just one dude with a job and a family so I literally just do it to help guys out. Lots of guys have put them together, I know you can too 👍
What Facebook group
Um, KJ Raycing 😉 😁
Where can I find both the tractor pto shaft and hubs???
Part numbers are in the plans so they are easy to search 👍
@@KJRaycing Okay, thank you so much for your help
Is it cheaper then buying one
Since you can’t really buy one it is a lot cheaper. And since you build it yourself you are not paying anyone labor costs, so an all around yes.
Will it work on a go cart
It will work on anything that has a chain. 420,520 and 530. Hub to hub is about 54” so it will be a wide go kart, but that’s not too terrible 👍