My OTK / Tony Kart Complete Build | GX-UK 2024

In this video, you'll watch me put together my 2016 Tony Kart Racer chassis from a bare, unpainted frame - all the way to a completely ready-to-race kart.
Please feel free to ask questions in the comments.
This is not designed to be a comprehensive and fully detailed guide, but rather a general helping hand and jumping off point for anyone building their own kart.
#OTK #Guide #Build
Join this channel to get access to perks:
/ @bradphilpot

[@FunkyKarting]

here to say thank you for showing us your ducks.

[@BradPhilpot]

They should have featured more heavily to be honest. They were supporting the entire build with their constant quacks! 🦆🦆

[@FunkyKarting]

@@BradPhilpot my thoughts exactly, the positive encouragement was heard throughout. Get yourself some mates like Brad's ducks. Great video mate👍🏻👍🏻

[@BradPhilpot]

@@FunkyKarting that’s really kind - thank you!

[@georgemassey4724]

Amazing video Brad lots of hard work been put in to the kart, looks mega 🔥. How much for me to send mine down for you to build to take in the new season? 🤣

[@thebner9767]

I am just about to do the same thing but I dont know where to get the parts!!! Any suggestions?

[@BradPhilpot]

Try UsedOTK and tell them I sent you. Ollie the owner will sort you out with everything you need.

[@Bossmann710]

How did you color match the original Tony kart green, you nailed it

[@BradPhilpot]

I can’t take credit for that - the paint guy just did it for me!

[@Scoobyivan]

Good going !!

[@pillowhead4000]

Kart looks amazing mate, top job!! I'm embarrassed by mine now, I'm just getting my kart prepped for Clay and was wondering how on earth do you change the sprockets with them being on the inside of the carriers? haha! Have I missed something so obvious???

[@BradPhilpot]

Cut them with a hacksaw and bend them over the axle. I have a video somewhere!

[@pillowhead4000]

@@BradPhilpot oh no way! I'll check that video if I can find it!

[@joshcowlishaw8635]

did you find it much cheaper building your own kart up rather than buying a add fuel and go sort of thing?

[@BradPhilpot]

Probably not - but it means I have full control over how it’s built and I know all the components and how they fit together. You could definitely do it cheaper. But this was fun!

[@ghost4004]

what series are you running that uses only 1 4 stroke engine? i have a Rotax on mine but only do practice days, as entering a full season is expensive

[@BradPhilpot]

It’s the GX-UK series. Probably the most affordable owner driver championship in the UK. Take a look at some of my other videos posted recently and you’ll see some of the racing and onboards!

[@rickyhutchings2263]

Hi Bradley great video just wondering where you got the mounts for the engine. Many thanks

[@BradPhilpot]

There are a few different types - but if you DM me on Twitter / Facebook I can send you the links

[@pillowhead4000]

Loving these videos mate! Top stuff! Out of interest if I’m weighing in at about 77 kg kitted up, how much lead would you approximate I would need? I’m going to try and stock up this week! Thanks in advance!

[@BradPhilpot]

Hello! You’d need about 13kg but some of that can be fuel. For reference I run about 15-18kg of lead.

[@pillowhead4000]

@@BradPhilpot thanks for that mate! I saw there is an option to run 150 with a restrictor, is this not a good option?

[@BradPhilpot]

@@pillowhead4000 I’ve never tried it - but all the top drivers are on the unrestricted engines so that might be an indication. I think it depends on the track whether that’s worth it or not.

[@luke86tomlinsonracing]

Appreciate the attention to detail! Good prep goes a long way. Kart looks good mate. Will be interesting following the season and how the class takes off. Already seems pretty popular! A slightly different approach compared to our prokarts. Reckon the championship will switch to the intermediate engines (R200s etc) for a little more umph?

[@BradPhilpot]

Thanks Luke! Not sure on the engine thing. Obviously more power is always nice, but the key to this series is affordability, and there are plenty of affordable GX200 engines around - which wouldn’t be the case with the new type I think.

[@KartingTrackGuides]

Maximum air time for the O Plate!

[@helmetculture]

How did uou refurbish the sidepods??

[@BradPhilpot]

Heat gun to remove stickers. Nail polish remover and a microfibre towel to scrub off sticky stuff

[@metalpigy]

Really interesting to see the whole build, great vid! Looking forward to seeing the results of your efforts when you hit the track!

[@BradPhilpot]

Thanks dude ❤

[@onboardcam]

Next time i should have take the axel out on the other side and slide in from the other side is much easier

[@Rob_Turner_UK]

what did you use to strip the vinyls off the bodywork?

[@BradPhilpot]

A heat gun and lots of nail polish remover

[@divee2]

What engine mounts did u use?

[@BradPhilpot]

7 Kart ones with 3 adjustment holes.

[@kieranshanks]

need a before and after photo for the season......... lots of trophies in between i'm sure 🚀

[@BradPhilpot]

I’m hoping it looks just as good at the end of the season, because I plan to stay on top of it.

[@tropiicul]

I am interested in putting my own kart together for GX-UK. But I have no idea where to start wtih any of it. Very basic mechanic knowledge, no previous owner driver experience. Any advice?

[@BradPhilpot]

You’re in the same or similar position to me a few months ago. I ended up finding these karts really easy to work on. Nothing complicated at all, and loads of help available online. In particular the OTKs are so common, that parts and expertise is super easy to come by. Feel free to private message me on any social channel (twitter, Facebook etc) and I’ll help you as much as I can - even in terms of pointing you towards the best kart to buy and where to find it cheap. I also have nearly finished building a kart to sell (video in the next few weeks on this channel) so if you wanted one ready built, there’s that option too.

[@forcedinduction2918]

Did you replace your brake disc carrier cause it wobbles ?

[@BradPhilpot]

No, just because I wanted a cleaner looking one. It didn’t wobble. The old one is now a spare.

[@forcedinduction2918]

@@BradPhilpot just out interest genuine disc or an aftermarket one 🤔

[@motorsportministries7843]

hey couple questions, first how can i see when you reply to me? Because I leave comments on many videos and then forget to check for a reply? I have a 2021 redspeed and my wheel studs and nuts have cost me so much money. I have had to replace OTK hubs because the hole where the stud goes is stripped. I stopped using an impact, I got all new studs, all new nuts, and I put them in. What am I doing wrong and what can I do to keep these good? What kind of nuts do you use for the wheel studs? How do I keep my hubs from getting so loose that I cant put a stud in there? Tired of replacing hubs.

[@BradPhilpot]

Hello! Super interesting questions @motorsportministries7843 - so I’ll try to answer: Firstly, KZbin should notify you when I reply. A little red dot should appear at the top in your app when you log into KZbin. OK - with regards to your studs: what tool are you using to fit and remove wheel nuts? I use the copper “K” nuts which are soft and don’t damage the stud thread as much, and I fit and remove with a hand-tool (a T-Bar socket) so I feel if I am cross threading and don’t damage anything. Make sure you’re turning the socket gently for the initial bite so you don’t accidentally strip the thread. If you email me photos of the problem to [e-mail], I can probably help you in more detail!

[@motorsportministries7843]

@@BradPhilpot thank you will do

[@kartaroundtheworld]

Nice video ! I'm impressed with the amount of weight you have to add to your kart as ballast !

[@BradPhilpot]

Thanks for watching - yeah it’s a lot! And a full fuel tank too 😂

[@kartingsniper4499]

What did you use to polish up the Sproket carrier and hubs?

[@BradPhilpot]

Hello! A wire brush on the end of a drill.

[@kartingsniper4499]

@@BradPhilpot thank you, also when you rebuilt your breaks did you change the seals and if so did it stop your breaks from biting. my otk breaks lock up and send me slightly sideways and upset the balance going into a corner but I tired a different kart and I could squeeze the break pedal as hard as I want and no lock up so much better. Thanks

[@BradPhilpot]

@@kartingsniper4499 I didn’t change the seals because they seemed quite fresh. But if your pistons are binding then definitely explore that option.

[@Ollyphotography]

Loved the video. I saw you had an official tony kart suit any idea where you got this from and if they do kosmic ones thanks

[@BradPhilpot]

Thanks for watching! I got mine on eBay second hand, but strawberry racing sell them new. Just Google them and you’ll find it. I’m sure there are also Kosmic versions!

[@HirdyGeneral]

great build Brad - kinda wanted to see a shakedown outside your house!!

[@BradPhilpot]

Shakedown video coming mid January!

[@grubbymangomotorsport3992]

Great work Brad, lots of effort going into your kart!

[@BradPhilpot]

Thank you ❤

[@punkypink83]

haha loving it. the colour scheme n deals make it the tony-est of any tony kart ive ever seen

[@BradPhilpot]

Thank you for watching 😊

[@leonfrancis5205]

Brilliant video. I'm officially naming it, 'The Mean Green Flying Machine'.

[@BradPhilpot]

Perfect name! ❤

[@leonfrancis5205]

To be used it all future Comms 😊

[@leonfrancis5205]

@@BradPhilpot Or 'The Mean Green Time Machine'.

[@trm2010]

Nice job Brad , Kart looks fantastic !

[@BradPhilpot]

Thanks Anthony

[@kye_Racing21]

The kart looks so weird without the livery

[@BradPhilpot]

Yeah it’s much better with stickers for sure

[@JackMichelson26]

great video mate!

[@HybridGt2052]

Why do you run 2 bearing rather than 3 on the rear axle?

[@BradPhilpot]

It’s a good question - I think it’s more common to run 2 from what I’ve seen, and the series I’m racing in uses Honda GX200 engines which aren’t very powerful, so I think we just don’t need the additional support. All the OTKs I’ve seen in this series only run the 2 bearings.

[@paulhandley1465]

Looks sick

[@CjBarrrie27]

kart looks brilliant but if i had a kart i could never do that haha :)

[@peterbradbury1592]

Great build job Brad, a lot of care and attention.

[@EmmieFloding]

Excellent stuff, I'm planning to put together a kart for the first season of GX-UK next year. got my fingers crossed that I'll manage to be on the grid but first I need to get a way to transport a kart and a place to work on it.

[@EmmieFloding]

btw any advice for ensuring compliance with the weight limit? with kit I weight 57kg so it's been tough to get enough weight on in rental karting when I've needed to.

[@BradPhilpot]

Transport is also an issue for me! Current plan is to put it in the back of my car, partially stripped down so it fits - or a roof rack - or hire a van (which is most likely for the season itself!) Please shout if you want any help with anything!

[@BradPhilpot]

Full fuel tank, plus lead on the seat in several places and the floor tray.

[@EmmieFloding]

@@BradPhilpot thanks, I'll be sure to reach out whenever I hit a snag

[@BradPhilpot]

@@EmmieFlodingplease do!

[@danielcataldi1630]

Dude! How much lead do you run?!

[@BradPhilpot]

Hey Dan! I have about 25kg of lead to get up to the 165kg limit.

[@BradPhilpot]

Oh plus a full fuel tank!

[@danielcataldi1630]

Hey Brad. Great build video, really nice to see you can get a kart looking great without just throwing new parts at it. 2 more questions: Is that a new chassis or a respray? & Does anybody bother threading the axle through the chain to avoid braking it? Cheers, Dan

[@BradPhilpot]

@@danielcataldi1630It’s a 2016 chassis, acid dipped and repainted. You can thread the axle through the chain, but it’s massively time consuming, and involves removing lots of parts which then need repositioning that’s all. Not an ideal job to do at the circuit.