How To Build a Go Kart Differential

An explanation of the differential setup on my independent suspension go kart. (Ratcheting diff)
Check out our Instagram: / the_dbr_garage

[@mitchodds]

I wish that there was some production version of this! Great idea!!! Simple yet effective.

[@gaspedalgarage7670]

Mitch Evens me to. There’s still some improvements I’d like to make but so far it has held up great

[@TheOldKid]

@@gaspedalgarage7670 i hope you've applied for a patent for the product or concept in some way. This has potential

[@benfala9984]

Dude this is unbelievable I have been trying to figure this out for a while and couldn’t think of anything besides just buying a real differential. THANK YOU!

[@gaspedalgarage7670]

Glad to hear I could help

[@not-stock]

It is sure fun to see somebody doing experiment after experiment to refine their design. It is definitely MY STYLE. Keep up the great work. Don't ever loose your talent for being open to suggestion. I see you responding to other guys inputs with "thanks for good idea" kind of responses. That is very cool and will take you far. Designers who cannot do that are stuck inside their own limited brain. Together we are much smarter stronger and faster than any one of us are alone. Nice project!

[@Fortnitlover3000]

This is great man, I finally got to watching this video and ur a genius

[@BreitfussJoey]

This is as simple as amazing. You re a genius!!!!

[@Liyingbemo]

Dude this thing is sick, i love it

[@Ozarkprepper643]

👍 Definitely a great idea. After reading through many of the comments it seems like many Overlook the fact that this is a inexpensive way to achieve excellent results. Although the sprockets are relatively inexpensive and likely easy to replace, curious how long they're wearing. I'm getting ready to start building a 4x4 electric Street buggy. ( yeah I can actually get it licensed if I follow a few rules) Although I could use any number of ready-made differentials, I always prefer to build my own parts. This system would work good for the back and I could still reverse using the front axle. What I had been contemplating is a ball diff. Much like you would find on some RC cars. Where you have a plate on each side of a main Drive disc. The main Drive disk has the holes in it that contain large bearings then you can control the pressure on each of the outside plates depending on how much differential lock up you want or need. And that pressure could either be controlled by a servo. It's not all that expensive or even really complicated the build. And also would be quiet with very little wear. I have been designing and building airplanes for decades. But I started building carts in the sixties. Never stop engineering and never be afraid to fail. I have a nice high Wing ultralight. ( j3 kitten). A superstol bush plane. Many one-offs on it. 16 in of travel on swing arms controlled by Fox air shocks. And the type 1 2300 has 2 AMR 500 superchargers with clutches. They work on a manifold of my own design. And feed 4 throttle bodies 1 per cylinder. This Plane can get off the ground in less than 30 ft. And the 3/4 scale all composite P-51 Mustang has a supercharged LS3. It well Cruz all-day at 318 knots per hour. And burns 21 gph on pump gas. 🤠🐂🏞️🛩️

[@TomBuikema]

Genius design dude

[@gaspedalgarage7670]

Tom Buikema appreciate it👍🏻

[@dfpguitar]

great topic for a video. Those birds beaks have a common name, which is a pawl. p

[@RyanGribble]

Pawl, the bird beaks are called pawls.

[@2SlickNick]

Okay subscribed... Great job DIY!

[@gaspedalgarage7670]

Thank you very much!

[@rome79735]

I like this I am watching videos like this one to give me ideas in building my own off-road go-kart.

[@gaspedalgarage7670]

Great, good luck!

[@cyrbrexx]

@@gaspedalgarage7670 cant find you on IG wanted to know if you are willing to show individual components of the diff working on a project and stuck on how to make the diff yours looks awesome

[@tuetis]

Yo this is amazing! I've been looking everywhere for a simple idea. You are super smart!

[@gaspedalgarage7670]

The Gladdens glad to hear you like it! Unfortunately since this video was made I put a little to much power through it and it broke ;( but eventually I plan to make a better version

[@ltaylor4444]

What broke?

[@gaspedalgarage7670]

Logan Taylor the bolts holding the “dogs” in place bent and caused the whole assembly to slip. If I designed it so they were closer it the sprocket and maybe sandwiched plates to keep the dogs inline with the sprockets the design would be better.

[@ltaylor4444]

@@gaspedalgarage7670 I wonder if you stacked some steel plates, welded them together, then welded it to the sprocket, then drilled a hole for a bolt, if it would offer more stability?

[@gaspedalgarage7670]

Logan Taylor great idea, there is a lot of things I think could make it better. Maybe some day I’ll rebuild it. For now I’m happy with the solid axle I put in. It still has independent suspension with cv axles but no diff. I was worried about understeer but I haven’t noticed any change. Right now I’m putting in a ninja 250 engine that makes a lot more hp, I want to make videos about it but I’m very busy!

[@ChuckStraughn]

Very nice!

[@NicHolmes]

I'm curious to know how that would work with reverse? Surely the system would free ratchet if you had a reverse gear? I'm trying to figure out how to build a chain style differential that can be operated in both directions

[@gaspedalgarage7670]

I’ve answered this question on a few other peoples comments, go check those out for a more detailed answer but basically it can’t reverse. I had no need to when I built it. It would be easy enough to make some type of two speed trans with one output going to the diff for forward and one output going directly to the axle for revers. Hope this helps!

[@shannongeisler6755]

So what would it cost to have you make and ship one? Great idea and design.

[@austinharris7178]

Could u give more detail as to how you attached the drive sprocket onto the axles. I understand the differential sprocket design I just fail to understand how the drive sprocket (middle sprocket with chain on it) is fixed to the axles

[@fuglyhippo7484]

Looks fun man! But, this elimates reverse and will not hold up long term. Maybe build a sprocketed cylindrical diff (no pinion, ring is replaced with sprocket) with encased spider gears. Just a thought!

[@joshmnky]

Is this unbearably loud? It seems like you could churn these out for cheap if the ratchet pawls were part of waterjet cut disks, cut from spring steel. You could have several pawls on each to spread out the force, reducing the noise and wear.

[@GhettoRanger01]

Great job, I like seeing people use their brain to solve mechanical problems. One thing though, wouldn't a weaker spring engage just as well with less metal on metal wear?

[@gaspedalgarage7670]

GhettoRanger You are absolutely correct. The pressure of the engine pushing those “dogs” drives them more securely into their positions. I didn’t know how well this system would work when I first made it and the heavy springs were simply a way to ensure the dogs would engage very quickly and never skip over the teeth. I have since removed this system with the hope of re engineering it. I will definitely keep your suggestion in mind. Thanks!

[@turbolaser24]

That is genius

[@vetta63]

Great design! Have you looked into replacing your setup with two sprag clutches (freewheel bearing) i think it will give you the same result but in a more compact design and with less moving parts. For your design when cornering do you notice a loss of power, because it is driving the inside wheel?

[@gaspedalgarage7670]

Jacob Najmy that would be a great idea, as of now I’m satisfied with the result so if I decide to rebuild it I’ll keep it in mind. As far as power, I have not noticed any loss. If you mean any loss of power due to slipping then also no. If the inside (powered wheel) were to lose power the ratchet would engage causing the power to be transferred to the wheel with the most traction. Thanks for your support!

[@robertpeters1809]

I’ve been wondering about using Sprague bearing as wheel bearings, keyed on inside and out. It seems this would work if one could find appropriate sized bearings to fit in wheel hub. Would like to hear more about this, using a live axle.

[@theflagstaffkid]

This is cool. The design appears to eliminate the ability to slow the cart by down shifting/ motordrag, great idea though!

[@gaspedalgarage7670]

theflagstaffkid yes it does, it’s a downside but I think it’s a good design regardless. Still room for improvement!

[@TheAussieincalgary]

I am thinking you probably don't have reverse on that machine. Terrific idea though. 👍

[@kevin6030]

how long do you think that will last I see a lot of metal filings and chips laying around but either way good job using your head keep it up and you'll definitely go far

[@jreynoldssroberts8581]

Good job. how do the sprocket hold up?

[@gaspedalgarage7670]

they have held up very well so far, only slight wear. I'm sure over time they will need to be replaced but it would be very easy to do with the design.

[@ianbuilds7712]

U were just talking about metal on metal contact and whatnot... Is there at least a bushing inside that center sprocket??

[@88s10Durango]

Great build and project ! I`m finding in your vids I`v watched the volume is very low when your talking ,, any chance when you edit you could turn the volume up a bit ?? thanks and keep the vids coming ..Bill

[@gaspedalgarage7670]

Bills BuildAll I appreciate the feedback, and I’ll be sure to make it louder next time. Thanks for your support!!

[@88s10Durango]

@@gaspedalgarage7670 I really enjoyed your videos , I`m presently just waiting on a few more parts myself on a project I started 4 years ago and then put away , just picked up a Honda GX340 engine , using a old spare XL350 engine block for the tranny & clutch , have 2 Honda Civic CV axles , and a new set of V Gorooved ATV tires and rims + a set of motorbike shocks for the front and gonna use a set of YZ front air forks for the rear .. keep your vids coming , cheers.

[@holleyciggy]

the encapsulated nuy......you could use a compression style lock nut

[@amateurastronaut5006]

Do you have to harden the bird beaks?

[@Benny-vn3mp]

Where would I get the parts you used to make one of my own?

[@patrickr7001]

Could I find a sproket like that or do I need to make one?

[@gaspedalgarage7670]

Patrick R I bought the center sprocket from go power sports . Com and modified it for this. If you mean the smaller sprockets you can get them at tractor supply

[@joshkelly3743]

How does the rear brake work? I only see one rear brake rotor

[@gaspedalgarage7670]

Josh Kelly that is the brake rotor you see in the back. It only brakes the rear right tire but I’ve never had any issues with imbalance or spinning out so I’m not concerned

[@kevin6030]

awesome job man you're on your way to being a very professional engineer you'll be working for Honda or Kawasaki or Yamaha one day. badass buggy design as well I like to build the same type of things and then destroy them while I'm ripping lol. keep up the good work you have a good head on your shoulders. 👍🏼👍🏼👍🏼🤠

[@marindelongcamp7385]

Hum...i have a question ( sorry if my english is bad im french 😬) ... If the If the inside wheel is the only one that is propelled by the engine when cornering, does the go-kart lose its grip on the road?...And if the engine is not powerful enough, is it possible that it could stall when it turn?

[@gaspedalgarage7670]

If the inside wheel were to lose traction the ratchet mechanism would “catch up to itself” causing traction to move to both wheels. And no it cannot stall with this engine because of the ctv

[@marindelongcamp7385]

@@gaspedalgarage7670 okay thanks 😉☺️

[@BreitfussJoey]

Maybe i subscribe in future😉

[@m3n4lyf]

Saw blades? Stacked saw blades?

[@gaspedalgarage7670]

Zed Smith Or a sprocket....... whatever you wanna call it

[@nuvey7939]

Any additional footage or design information?

[@gaspedalgarage7670]

Nuvey if you are referring to the differential, no. It worked well for low power applications but I have a ninja 250 engine in a complete rebuild of this buggy and the power was to much for this diff. I have a solid axle now and it still drives very well

[@supervagao]

How can you reverse?

[@gaspedalgarage7670]

Carlos Super Vagão Fagundes at the time when this video was made I really didn’t need (or have a way to reverse) ie. the engine didn’t have a reverse gear... so it wasn’t a problem. Now that I have redesigned it I would like to put reverse in. This can be don’t by placing another sprocket on one of the sides that goes to a reverse gearbox but as of now I have not done anything.

[@patrickr7001]

Is there a way to lock the diff

[@gaspedalgarage7670]

Patrick R the diff is always locked in a way. It allows the wheel to turn FASTER, not SLOWER like a regular diff... that means that if the powered wheel loses traction the mechanism will catch up to the dogs on the other side applying traction to both wheels. Basically there is no way for you to spin one tire with this design

[@jimhenson7947]

What shocks are you using

[@gaspedalgarage7670]

Jim Henson super cheap Chinese ones on amazon

[@murauder]

Can the vehicle go backwards with this setup?

[@gaspedalgarage7670]

Not if the power goes through the chain. You could go backwards if a separate sprocket were mounted directly to one side’s axle. There was really no need for it to go backwards at the time so it wasn’t a problem. Since this video was made I’ve converted back to a solid rear axle and didn’t notice much of a performance change. I still haven’t built a reverse set up but I have plans for electric reverse in the future. Thanks for watching!

[@murauder]

@@gaspedalgarage7670 thanks for the response I kinda figured. Did you go back solid because you broke it or just didn't want to have to worry about it?

[@gaspedalgarage7670]

Both😂. I broke it with a launch(not surprising) and just figured I’d try the solid again. Maybe some day I’ll revisit it and make it able to handle more power but I’m satisfied for now👍🏻

[@jameskevincassion6653]

its ok to reverse？

[@gaspedalgarage7670]

Checkout other peoples comments where I thoroughly explain that it cannot go backwards simply because I had no need to reverse when I was building it.

[@charlesthurston5172]

i would have made 2 discs to put on either side with bearings on the drive axles and machine sleeves in place of washers to space the outside discs from the rachet mechanism then put a long bolt through the the outside discs, rachet mechanism, and sprocket to make it stronger and with that you could make the racheting mechanism a bit bigger

[@gaspedalgarage7670]

there are a few modification I would like to make or have already made to the original design! thank you for great idea!

[@charlesthurston5172]

@@gaspedalgarage7670 i just had a thought, is the sprocket that the chain goes on where the rachet system is have collars on both sides if so you could add 2 extra discs to encase the system you may have to fabricate longer bolts to get it to go through 4 discs and the sprocket and if you use the idea i had from the earlier comment i made by adding 1 more sprocket to each rachet gear on either side and doubling the hook size, and also by adding 2 more hooks because you would have to get or fabricate 4 long bolts to hold it all together the 4 bolts would have to go through the entire system or it might warp the sprocket the system would be strong enough to withstand more torque

[@gaspedalgarage7670]

that would be a great idea! at this point the power is not high enough to warrant any additional strength.

[@fredhinck8847]

Kinda like an old David Bradley walking tracror.

[@fredhinck8847]

Can't seem to spell TRACTOR

[@unclejerm7692]

Wish I could hear you, motor sounds are loud but I cant hear your voice at all.