KTM 525cc Cross Kart Build!

that's what it is it's a vf1 variable frame crutches laying on top of the chop Sal couldn't have done it without you guys I want to thank my mom we need different tabs what do you think it's real nice real nice today on cars and cameras we're building a vf1 crosscar out of this 525 Polaris Outlaw let's get [Music] started cut off cut off all right guys timer starts right now so 72 hours we're going to have a new fast vehicle around the cars in cameras Grand Prix the vf1 cross car so we got the four-wheeler being taken apart we already had to build a jig here and I had to make the biggest Amazon order I've ever made in my life to put the rest of this thing together we're going with the KJ racing vf1 plans Kyle and Dave they are the masterminds behind this chassis and they are with us here and they have brought some other machines we're going to check out as well we got the Geniuses here we do has anybody SE has anybody seen my hairspray what is all this commotion going on all right well let's meet the Dream Team chuck all right it would have taken the three of us months to build a new cross cart but with the help of our friends we think we can do it in just 72 hours the only thing we did before this week was bend the chassis tubing and order parts you can check out how to bend the chassis on Kyle's [Music] channel here we go cool the weld we're going to weld one side in all right so much come probably need to file out those so Thomas and Scott jumper cable dads that's us nailed it what good intro see both of you guys have built one of these crosscards kind of what all are we using other than the engine uh the front end the suspension from the front end and then the suspension from the rear end and that's about it and the gas tank and the radiator and the spool apparently we're using more and the wheels that's about it cool think we're halfway there I think we're almost done all right so this is Kyle hey uh yeah he's the uh the Kyle and KJ racing and uh dude thank you for he came down from upstate New York to help us build this thing this week and are your plans and so tell us a little bit about them so I built this on my own about 4 years ago and some people saw my work and wanted me to kind of refine it and put it out so other people could build it so that's exactly what I did I made them a little easier to build everybody's put their own spin on it different engines different suspensions different tires different ideas of what they want to do with it uh buggies cross carts and it's it's such an unexpected adventure I didn't expect to for this to all take off from just something I wanted to build in my own garage so that's what it is it's a vf1 variable frame is is what I named it and it's basically just cross cart fun so I marked this before I bent it notched it's C12 and my PL it's C12 you see where that is so it's just the right side front I'm just paper W around the tubes so these are the notch wrappers uh you basically set a line for the outside Bend radius then you mark a distance from the end you tape this to it and you cut it at a certain angle then you clean up your Notch by the black line on the cut wrapper and then it just goes right into place it's like a really big jigsaw [Music] puzzle the Polaris Outlaw 525 is the perfect donor vehicle because of the independent rear suspension it makes 45 horsepower in a small package it has reverse and you use the entire front suspension it basically saves you a lot of time of cobbling Parts together two big moments at the same time we're almost done after this guys he make that look heavy he did have a hernia why is the guy can't figure out why hey that's why we like the 525 you can pick it wow that's actually it's pretty light right all that all that power it's a lot of juice and it's just slightly bigger than a 212 that motor would take the four-wheeler up to 90 mph it's going take a cross up to 9 mil so the chassis is at a point where we're happy so now we're going to work on the KJ racing home brew rear end so this is a lot simpler than using the um the outlaw rear end ever happen to you guys yeah yeah yeah I couldn't get the uh the nozzle to clear out so I just kind of went with it yeah we're going to we're going to go with it C looks pretty flat you know it [Laughter] does okay so you can well half that flip it well and half that or yeah we don't want to C kind of stitch it yeah good morning dune buggy Dave morning how we doing a little too early to tell but looking good I hear you what are we doing today I am scribing radius on these tubes for bending and notching nice oh look who showed up old coyotes are us what's happening left the door unlocked we tried to get it done for you sir but we just you know I think everyone went on strike last night I don't think one day is going to get one built I don't care how many guys are here one day is asking a little bit too much maybe two it's cuz you weren't here yeah that's what it is I kind of doubt that cool for tie rods I'm going to put the shock in so we can make sure that the shock has plenty of clearance that's a good rule it many people the Caster would be if as long as the floor is level it should be set however well we can do that oh yeah yeah so this gets the camber in in check yeah for zero camber yeah but Caster is uh or if you want some negative cam we can put some washers here so we've got the uh the ball upper and lower ball joint so if we find something to fit there and then we can and this is showing eight so maybe it is eight okay so we'll just set this to eight so 6 to eight I'll go eight I'll go the same as that the match of these is going to make it this all easier I'm going to find something flat to put here okay and then I'll set it probably get a couple of boards and set up the top too yeah so I like to do the wheelbase by size of tire I'm running so that it hits the tire before this so if you knows over this isn't digging in right flipping you over how the wire pedal going to go pedal and Ste we got this for the steering rack oh you're good I'm getting the notching done what all do we have to notch so right now I'm on the the rear control arms so everything's already been measured just placing the cut wrappers on putting them in the notcher and knocking them out sweet so the front end is done now we're working on the rear control arms we're working on the rear end so the rear a arms just consist of eight bent and Notch tubes they're assembled and they fit on the frame really well uh these can be used for either the outlaw rear end or the home brew uh tabs will get welded onto the end of here for whatever carrier you're using sweet they're fully adjustable because there's High on this side and they're pretty easy to make yeah and having these uh jigs we can have a symmetrical rear in what are you boys working on it has been a lot of notching and grinding and fitting and notching and grinding and cutting and bending today I have the uh the rear uh control arm uppers and downers if you know what I mean for the for for the shocks yeah or for the control arms the upper the upper control arm the lower control arm and there's some kind of adjustability in here yeah so we can increase or decrease the spread of the control arms at the chassis if we want nice so I'm kind of dehydrated you can tell yeah I didn't know I walked in on a chich and Chong episode so we're just going to kind of line it up with the front here so it sits on here and then make the upper tab off of that yeah okay then the lower one is just going to be a plate [Music] here okay too easy right but we need to hold this just so we can do this and then we can finalize the back uhuh I like BL so we're about 18 build hours in Scott where we at all right so bending and notching check attack the chassis check front end Mount done control arms done rear re spool is done yep spool is in okay and we still have a lot we only got half the suspension in so yep yep yep half the steering did you call her yet got to call her again okay so got to do that so we're going to come up with some seat brackets this is when we choose how much tilt we have on the seat and more tilt is going to help CER Riders fit better and we want to make this kind of universal yeah so this is pretty upright so this is like the standard position that it comes and you have adjustments on the seat itself but we can make adjustments from the frame piece as well we just scoot this too up and that'll give us the sweet bingo I don't know if you're going to yeah with a helmet I don't know about that my helmet's hanging out so you just get half an inch shorter if you flip over yeah you're fine fine you me helmet you want helmet 270 oh my God your microphon or earbuds out of your helmet what you dro the seat I thought that was a heart monitor I thought it was an eye patch yeah or we can wait the the the seat has a removable bottom you've been watching take the cushions out yeah let just take the bottom out of the seat take the cushions out yeah drop your it's got suspension yeah just just just make some of that caring foam yeah one of those oh so cute it's I mean I love how dude it fits really well Rush sr1 is that where you wanted it or do I need to back oh it goes back so the seat can go back quite away your Tabs are like dude like I got a Z28 sitting outside we can pull the motor out are we not supposed to directly at you get nervous yours doesn't seem as bright as mine nether it uh too much yeah too much [Laughter] okay looks good okay how to not get invited back are they supposed to be even master class on how to not get invited are they supposed to be even I imagine so uh not the tabs the bolts we measured the bolts but we can we can level these yeah there you go okay ready cover all right let's flap them flop them if you got them fly away let's flap them oh man we locked it together no look at that you Lo that Happ did it break that there it is no it's good L these end pieces up oh okay now now this thing looks like an oh yeah yeah red leader it's X-Wing X swing it come from back here and then if you spread them like 45 and 45 it looks like an xwing oh yeah all right what is that star Tru no that's St oh axles nice yeah Suburban axles Suburbia axles so the vf1 uses Miata rear axles for the home home brew spool very cool H they won't fit in the hubs o it's easy too the car axle going into an a UTV Hub I mean it eventually it'll fit in the hub right Machining custom Hub should be able to don't even have Hot Tips hey that could be a trophy part yeah exactly that's nice trophy now you have a new Hot Tips all right let's order a new boot no there's a spare me out hey a you just needed some uh some anti- encouragement yeah anti- encouragement okay so they're finishing getting the pedals set up we've got to put that in once that's in then we can start worrying about getting the mockup done for the steering shaft the steering shaft's going to come up that's why we have to have the pedals in place so we've got clearance for the steering shaft then it'll have a U joint around this area comes up mounts to the bottom of the dash to the steering wheel that way you've make you're making sure you've got all the clearances you need you've got driver room all that stuff so yep that might be too far back I think we've got a lot of room to come forward Charles want to jump in okay me personally I like to use this bar as a heel yep heel Place what's going on I like to put on the back of my heel to figure out a pedal box pedal placement to clear where the ujoint needs to go uhhuh it's too far yeah it's too far forward for him so yeah so you can put the back of the seal on there yeah that might that would that would do yeah I mean are we is there a plate that goes over that or is it over uh this bar is going to end up up there so you'll be able to put your heels between this bar and this now is that center line up front this steering shaft that looks pretty good so tight you going to hold it you got it yeah good okay that shouldn't break yeah but I can't tell if it's inside of here okay we need to take if you can if you can uh but this right up to this that'll keep it from moving oh slid it's touching that's what happened pull your end out so uh pedal box is about to go in for the final time we have our flat bar drilled and we're just going to plop it in there oh no can't do it cuz it's got to go up from the bottom so we need to install the hardware or the whole pedal box you could probably put it in for the bottom we did just come up on the jack stands we'll do that cool look how pretty that is lock lock nice nice quick ratio too oh yeah I think he said it's what 3/4 lock the lock yeah oh so you shouldn't do a you shouldn't whack your elbows trying to steer yeah sweet all right pedals are tacked in about to mark for the steering that's good oh yeah big moment here front suspension is going on the ground for the first time we can check our droop our bump steer and we can adjust alignment and we should be able to get bump steer out of it too with the way the steering KN works so ready oh yeah good you want to do the honors jump on oh you want me to jump on yeah oh that's so s nice yeah oh man yeah oh yeah that's not yeah only reason we don't have that tack cuz so we do align cool yeah that is awesome can you just turning it by hand sitting still exactly it's going to be like butter driving oh yeah yeah it feels like it has power steering in pretty good yeah we need to tow it out we can get it eyeballed and Tack the steering wheel in then get it [Music] perfect good yes no it's on it you feel that good yeah no just like some dude is donkey kicking a wheel on a cross cart and knocking over the crutches laying on top of the chop Sal you guys welding with your hands just using the for yeah I'll take it right Scott earned his wings this Gap W Wings thanks I couldn't have done it without you guys I want to thank my mom I want to thank my dad I want to thank my sister my brother my aunt I couldn't have done it without my uncle don't forget about your pet fish and Mountain Dew Mountain Dew monster cover good here we go C yes we need different tabs yes different tabs is there a nitril line or is it air I don't know it's it's fle Mall Edition yes all right yeah I want to see this thing on all four do it yeah we have ourselves a roller a fullon roller stand on the back yeah I just don't know where let's bounce let's bounce together oh the engine all right that's pretty good I was standing on the control arms and it was nice job bud nice job put her there thank you thank you Scott put her there Thomas put her there bud Chuck Nice Kyle all right [Music] nice day three was our longest build day yet our goal was to not only top the cars and cameras Grand Prix leaderboard with this cross cart but we also wanted to leave room in the schedule for everyone else to play around on the cross cards they brought we built from 9:00 a.m. until 2:30 a.m. hoping for at least a test fire at the end of the workday unfortunately there were just too many finishing touches so it's uh what day three on this no this is day four holy cow it's only hour like 35 though okay so I think we've done a lot of uh progress normally one of these builds takes like 6 months8 months uh and we've uh crammed it all into 4 days so far I have a really good feeling on getting this thing running and actually riding today really that is ambitious how's that wiring cooling system brake lines a lot of welding all right we got this dude before the sun goes down before the sun goes down this thing's going to be driving out the door okay oh ye of little faith man let's do it so so right now what I'm working on is the rear brake placement I'm going to have to add some like little shims in here and uh then we're going to have to probably work on some Plumbing for the brakes got the chain in and tightened up we got the upper yeah those are nice oh well thank you I worked really hard at it had the tabs welded in had all this uh tightened up it's uh it's looking pretty good I'm I'm really digging this thing yeah it's coming along it's a good build I like this so you're saying number one on the leaderboard baby yeah number one by the end of today let's not rush into things we can take it on his first test drive and then tune it tonight exactly and leaderboard in the morning there we go so uh next is uh installing the exhaust Scott here is he's going to be centering the muffler up the best he can out the back and I'm going to try to line it up over here throw some tack welds on it yes yeah it's the same way and then do a final weld hopefully it's going to turn out a okay all right so we're moving on to finishing touches I is working on brake lines uh Dave and Kyle are working on the shifter and the E bra and so we're choosing our height and position of the shifter you like that about right there yeah is this where it is on your so let's fit it to you do you think it should be lower I mean I I kind of like I kind of like it high you want that to the to yeah okay and I can always make it shorter if I need to the hood and floor pan installation really made this vf1 look complete the seat went in for the final time and I spent the better part of day four building a [Music] [Applause] dashboard Dash is going in for a test it's pretty much ready to get bolted in all right here we go all right okay you can turn it LO okay you now have a jack stand on thep Thomas is that is that welding slag that's been burn through your sock I I can nether confirm nor deny this is a really sweet Hood over for yeah this is welded in went through I just welded it in let's see final weld up check Thursday afternoon so officially 4 working days but about how many hours start what we say we were in 58 hours 58 58 working hours brakes check controls check body panels modified we got a hood all that's left is to send it and fix it send it and fix it let's go speaking of Swag what is this oh man what I survived build week everybody's logos no that is awesome dude that's killer Yes yes I got one for everybody so just tell me your size extra small large massive going to show off my P so after 60 hours of work time a full tank of welding gas at least six cases of root beer uh and at least 8 pounds of welding wire and maybe 12 hours of sleep this week uh we are ready to fire up the crosscar first I just want to say this is a this has been a a very special week one of the best weeks of work I've had in a long time we have I don't think we've ever thrashed this hard nope Charles no no so thank you guys for being here yeah thank you John of course guys yeah um so we ready to fire it up okay and if it survives the fire up and put around hot lap okay sounds good we got to get it to number one on the leaderboard that's right hit it all right uh choke on chokes on fuel on fuel's on y'all watch for smoke all right oh we'll see it it's going to smoke yeah if it comes out we'll see it key is on it's on run here we go do I need to give it in gas or anything probably maybe one or two times out I guess we need to see if we got spark not a bad idea anybody got a screwdriver I can get one uh uno momento guys I think I know what it is that's real really I think the coil's grounded wait what I think the coil ground tie the coil yeah you want some alligator clips so that's what grab that screwdriver check it is that a big enough ground oh you got a screwdriver you get a screwdriver just check it yeah okay just one second it was one or the other we didn't know all right ready yep cranking oh there it is I think the gas just need to get there wait what you do scri over there crank it crank it just turn oh yeah that's right crank it yep or does it that was my fault I let off the gas you ready yep I love it right in my ear the poop out of him now take the choke off take the off off yeah yes might have to turn up the ID idle cuz we did Wow We R without now too I'm going to crank it all right turn it up until it's start D I know I'm off the gas that's about it right there y face not break it uping I forgot about the it's not it's it's changing not it does not like to be we worm up a while driot it's the fitting on the Ben Hill line luckily it's not the sler okay cool I can let go yeah it actually feels like really good yeah is oh no got being neutral NE what neutral override that didn't take long it's okay this is why I put a neutral override switch in's light I don't think it's broken right no your hand more minutes left yeah you're missing it maybe shouldbe we should invite Charlie [Music] he's like oh holy there hey that was really cool po we did it we did it poor Kyle oh my sorry awesome oh man no way that was classic he completely covered him and was like I'm sorry and then did it again W and then he repeated what's up say I just stopped before I tore it up I number one on the leader board he came back am I taking this yeah sure okay awesome dude this thing loves to eat yeah well it's the stock gearing of the bike yeah with taller tires yeah usually you get away with second by yeah bigger sprocket but this is going to do over 90 yeah hey this thing doesn't feel like it's overheating or anything no check there's there's a light here's your indicator right here you probably can't see it um neutral is all the way over here cuz I experienced this once we should support this somehow hose clamp zip tie abolutely the weight of it bouncing around mine flew off okay didn't that happen at bus so hose clamp hot lap hose lamp hose lamp hot CL zip zip tie hose lamp hot CL a uh we got to take the sway bar off too yeah acket broke the yeah ripped it off loost the bracket ah y dang set [Music] a dang boy what was it I say it all just wait let's all go inside we're good we good let's go let's go check out the time all right we going to check out the time yeah let me put this in reverse and I'll meet you there all right the other reverse so I just got back from my hot lap I feel pretty good about it but there's still a lot that needs to be done to this thing so uh I feel like there's a lot faster time that we can get with this thing so stay tuned for the next video on this cuz I'm thinking at least a couple more seconds so speaking of seconds I want to know what my time is so guys can I get a drum roll Charles all right so the cars and cameras vf1 cross cart you did it in a 4779 yeah yeah oh God it won't work let me help you I can't okay there we okay there we go I didn't want to stretch some my push it further wow that is fantastic that is cleared it by about almost 5 Seconds almost 5 Seconds faster and I know I've got more in it we just like eyeballed the alignment yeah you know there's so much talk about that yeah yeah there's so much we can do the the sway bar actually broke on my Donuts out there so so I did that run without a sway bar in it and I can tell there was some definite body lean on this thing so I think a sway bar is going to help out a lot oh yeah so I got to say thank you guys for coming out and helping us with this this build I can't believe we did this in a week actually a little bit less than a week if you think about it yep uh it it it's a good feeling to know that we are loved that much so thank you guys and make sure I want each one of y'all to like say to the camera camera who y'all are and what channel yall everyone's got to drive it too yes also um I did the math yeah if you were to pay a shop 100 bucks an hour to do this we're at about $48,000 in labor this week you made out so send the bill to Isaac yeah yeah so Colin how about telling them uh who you are and what channel you can check us out at rattle Canan Customs 2018 I'm Scott jumper cable dads Thomas jumper cable dads Kyle and Dave KJ racing John from rattle Customs 2018 sweet be sure you check out a link in the description to the uh KJ racing vf1 plans build one yourself so uh John I think the only thing that's left since it's yours I think you need to do a 46 I think you at least need to drive it around all right absolutely oh yeah hey [Applause] [Music] [Applause] it now it probably won't crank back up but man that thing's pretty cool absolutely [Music] what do you think it's real nice real nice welcome to the family yeah thank you thank you guys for being a part of the community so awesome thank you for having us yeah this is insane it's like one of those moments where you like think back about like how you got here you know what I mean yeah it's crazy so do you think you can beat 47 seconds H probably probably yeah I know you can I know you can buddy all right get [Music] set [Music] [Music] a that's a lot what' you do that time he's faster faster than last lap yeah well the Fan's running yeah what do you think Bud uh I think I'm really excited right now and maybe not the cleanest driver huh what was it you're fastest was 4896 seriously yeah how' you do that you were even in the grass look at the ar ar yeah I don't know I can't do that that's took fell what I got to do it again are you serious yeah are you serious do you want me to get in a different place or Finish Line oh it doesn't matter okay if you get back in that Creek you can see straight down that line with him running that swall them and everything coming out nice perfect view good okay up PCH Hill oh go go hey we give him give him a minute he wants to get you going up the hill all right he ought to have enough time to get there he R pretty fast he do [Applause] [Applause] that [Music] [Music] [Applause] [Music] [Applause] that sounded faster it was still not faster you so mad were you in the top of third or top of fourth at the top of the hill uh me yeah I think I was in fourth I can hear it yeah it's it's only third you're not you're not getting Full Throttle you the the the cable stretch okay you're not getting Full Throttle I can hear it yeah it's hold on let me let me see that's it floor oh this very start yeah hit that gas first turn you're letting off way sooner than he did on the oh before the first Corner the very first throttle and see if it pulls oh the bolts loose so it's also going down you're less than half a second what size you need uh 7 if I get Full Throttle 716 it's like I can hear it yeah yeah all right well uh there you go John thank you but you got to give these other guys a chance oh yeah yeah we need so after a week of 16-hour days it was finally time to play we drove the KTM 525 a Yamaha 600 a Kawasaki 1100 and a budget Predator 459 cart with huge tires if you're looking to build a vf1 on a budget we highly recommend the Predator 459 version anyway it was an awesome week let's give a special thank you to the [Applause] [Music] team [Music] [Applause] [Music] m [Music] [Music] no break oh [Music] so that was a heck of a week it was definitely the hardest we've ever worked to pull this off in just four days absolutely insane we have a ton of content planned for the vf1 cross cart with the 525 I want to check out the big board kits but we got to wear out this 525 first right buddy that's right so for Just Two Weeks we're going to put a new t-shirt and sticker pack on our website cars dcas.com to commemorate 2023 build week we're going to change it up from this design so it's going to say cars and cameras build week 2023 with everyone's logos on the back only available starting today until January 3rd and we're also going to throw in everyone's stickers from the build week as well so the rattle can Customs KJ racing of course the jumper cable dads and two cars and cameras stickers so these shirts are only available for a limited amount of time again that's only 2 weeks and no they're not going to be here by Christmas unfortunately but it's going to be that perfect late Christmas gift that we're all guilty of myself included so leave a thumbs up if you've enjoyed this build this video today and go to our website cars dcas.com it's a great way to support cars and cameras and support all these guys that came down and that helped us out this week as well be sure to check out their YouTube channels they have some really funny behind the-scenes content and their own builds as well that are very well worth checking out anyway thank you all for watching again we'll see you next time oh and Merry Christmas I guess this is our last video before Christmas oh wow I didn't think about that Merry Christmas Christmas happy holidays it's been an awesome year we're off tomorrow morning early shooting a cars and cameras special that's going to be coming out in January busy times hey man give our fans a twirl dude give them a twirl oh yeah woo pick one up two weeks cool thanks this is from our buddy Kevin which oh gosh it's a motorcycle in the back it's all it's a Russian your come from yeah it is every single one it's a Russian Magazine from like 1980 dude that helmet is a open face with a chin strap click on that's cool what is that ah yeah I don't show them the cross card yeah that's sweet it's a air there's all kinds of bad ideas in this book oh Cru missile perfect where's the cross cart there we go nice no way yep that looks familiar yep so Kevin told us we we should have a series where we build a cross cart a Soviet cross cart

Channel: CarsandCameras

Views: 332,801

Keywords: cross kart build, how to build a cross kart, Ktm 525 cross kart, polaris outlaw cross kart, cross kart

Id: QdcrXylkzms

Length: 52min 7sec (3127 seconds)

Published: Wed Dec 20 2023