How to remove bumper rubbers / top tip for getting the rear bumper rubbers into the chassis
To remove the rear bumper rubbers, here are two recommended techniques:
1. Remove the nut and bumper rubber spacer from the bolt. Push the bolt into the kart frame through the bumper rubber. Insert a spring puller tool all the way through the empty hole in the bumper rubber and hook it in until you feel resistance. Pull the rubber out of the frame, then lift the front of the frame up to allow the bolt to drop out of the frame.
2. Remove the nut and bumper rubber spacer from the bolt. Insert a small flat bladed screwdriver (or something similar) at various points around the edge of the bumper rubber where it makes contact with the frame tubing. Pry open a small gap and spray a lubricant product such as WD40 or GT85 into the gaps, gradually working this around the edge in various places. Once sufficient lubricant has been applied, the bolt and bumper rubber should then pull out, usually by hand.
To get the rear bumper rubbers into the chassis, ensure no nuts are tightened onto the bolt prior to installation, as this can compress the rubber and prevent it from entering the tubing. It can be helpful to apply a small amount of a lubricant product such as WD40 or GT85 to the rubbers prior to install. Push the rubber into the frame, add the bumper rubber washer and first nut, threading it on until it meets the washer and you feel light contact. The washer should fit flush in the frame with no bumper rubber showing — you can then tighten the nut up to compress the rubber, which will hold everything in place.
How to adjust the nosecone angle
To adjust the nosecone angle, loosen the two nuts and bolts on the top bumper rail loop which connects to the frame. These are slotted holes, so this will allow you to slide the bolt back or forward, which adjusts the nosecone angle. When you are satisfied with the angle of the nosecone, simply tighten the two nuts and bolts back up in position.
What if the rear number plate tabs on the rear bumper are facing downwards instead of up? Is that ok?
This is fine, and simply a cosmetic difference.
Our sidepod bar holes don't line up with the chassis holes. What do I do?
If the sidepod bar holes do not line up with the chassis, mark the required sidepod bar whilst it is fitted in the chassis tubes. Then remove it and drill the new holes. It is also possible to drill these holes whilst the sidepod bar is fitted to the chassis, however there is a risk of damaging some of the paint.
Our sidepods keep coming loose on track. What can we do?
If the sidepods are coming loose due to the nuts and bolts fitted to the sidepod bars coming loose, you may need to use longer bolts with new nyloc nuts, to ensure the bolt is going all the way through the nut and engaging the nyloc.
If it is the plastic sidepod itself that is coming loose on track, it is advisable to apply a low/medium strength threadlock to the bolt threads prior to tightening them up — this will help prevent them coming loose after fitting.
What is the perfect position for the Nassau panel?
The Nassau panel should be fitted in a manner that allows sufficient space for the driver's hands at all positions on the steering wheel. It should also ideally allow the driver to see directly in front of them over the top of it, and not be above the top of the steering wheel when looking at the front of the kart. The bottom of the Nassau panel will naturally overhang a small part of the nosecone, and is intended to do so.
What if my floor tray holes and tabs don't all align?
If not all the holes align, it is advised to try and align the front or rear holes up first, to ensure the floor tray is central and square in the chassis. It may then be necessary to mark the required holes on the floor tray for any that do not align, remove the floor tray and drill new holes. The floor tray can then be fitted.
Fibreglass safety
It is recommended to wear suitable work gloves, eye protection, and if possible a mask when dealing with fibreglass — especially when drilling or cutting.
- Respiratory issues: inhalation of fibreglass particles can irritate the nose, throat and lungs, potentially leading to chronic respiratory problems.
- Skin irritation: direct contact with fibreglass can cause itching, redness and rashes.
- Eye injuries: fibreglass particles can cause severe eye irritation and potential damage if proper protection is not used.
- First aid: in case of eye contact, flush with water for at least 15 minutes and seek medical attention. For skin contact, wash affected areas with soap and cool water.
- Work environment: ensure adequate ventilation, use local exhaust ventilation systems, and avoid smoking or using naked flames in the working area.