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Summary of Contents for Flatworks plyfly
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HOW TO BUILD YOUR PLYFLY GO-KART! For Ages 12+ PlyFly Go‑Kart Instruction Guide • 2015 Release...
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Thank you We hope you’re as excited to get started on your new adventure as we are to be working on the FLATWORKS. Enjoy your new Plyfly Go‑Kart! Check back soon and see what else we make! the Flatworks Crew, &...
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Steven Hynes Cam McCulloch K Brotman Alan Miyasaki Dennis Cox Stephan Schnitker Chris DePerro Chris Patton Family Woo Joe Barton Marcus Leef Liam Newman Tyra Hammett Mohit No Regrets Nathan Pelsor Sam Bell Ray Colwell Douglas Dayton Emily H. Henry E. Sam Bowling Andrew Marc Carl Moulton...
What's Inside? 1 Exploring the kit 8 Pedal Assemblies Warnings and safety Plywood sheet reference Handling and storage Recommended tools Why Wood? Required hardware Good to know Required wooden parts What’s in the kit? Assembling the gas & the brake pedals Unpacking the boxes 9 Frame Assembly 2 Getting Started...
Exploring the kit Introduction Each Plyfly Go-Kart kit arrives in 3 boxes. Review the contents of each box to ensure you have all the necessary parts to begin building your next adventure!
Warnings and safety Handling and storage Riding karts can be dangerous. • The kart is heavy. Please use caution and prudence and follow the • Use at least two people to lift or move it. guidelines below. • Some surfaces may be hot after use, handle with •...
What’s in the kit? Sure, steel karts are fun and strong, but they require a large Each Plyfly Go-Kart kit arrives in 3 boxes. Box 1 is a flat box number of specialized tools to build, repair or modify. Tools with the wooden structural parts.
Unpacking the boxes Each box should have the following components. Box 1 contents 2.5 HP 4.0 HP 4.0 HP 4.0 HP 4.0 HP SINGLE WHEEL SINGLE WHEEL SINGLE WHEEL LIVE AXLE LIVE AXLE № DESCRIPTION 10” WHEELS 10” WHEELS 12” WHEELS 10”...
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10” WHEELS 10” WHEELS 12” WHEELS 10” WHEELS 12” WHEELS DESCRIPTION Plyfly Packaged Hardware Kit Sealed kit of go ‑kart hardware Clutch #35 Chain, 11 Tooth Pulley for 5/8” shaft 2.5 HP Model ― ― ― ― Clutch #35 Chain, 12 Tooth Pulley for 3/4” shaft 4.0 HP Model ―...
Getting Started Introduction Preparing for a Plyfly Go-Kart build, you will need to cut out each structural wooden part from the plywood sheets. The more time spent trimming tabs cleanly will save a lot of sanding time.
Orbital sander Sandpaper Jigsaw or Reciprocating saw (optional) For more information on What’s in the kit?, see page 3. PlyFly Go‑Kart Instruction Guide • 2015 Release...
Seat Assembly Assembly Introduction Before beginning this assembly, be sure to chisel out and sand parts 22 ‑ 33. These 12 components are required to fully assemble the go‑kart seat...
PLYWOOD SHEET 3 Note If you received a 1/4” plywood sheet that is finished on one side and you intend to paint the Plyfly go-kart seat; reverse the wooden parts 28-33 (so the unfinished side is outward facing and ready to receive paint).
Note the location and orientation of the part 32. 14. Repeat step 13 with part 30 on the opposite side. 15. Secure parts 30‑31 to seat frame using screws. ‒ Use 4 screws. ‒ Total of 4 locations. PlyFly Go‑Kart Instruction Guide • 2015 Release...
Steering Column Assembly Introduction Before beginning this assembly, be sure to chisel out and sand parts 19‑20. These 3 components are required to fully assemble the steering shaft.
Assembling the steering shaft INSTRUCTIONS 1. Press bushings into each side of part 20. 6. Secure the parts using screws. ‒ Use 2 screws on part 20 Note there are 2 bushings, 1 bushing per side. ‒ Total of 2 locations. 7.
Steering Rack Assembly Introduction Before beginning this assembly, be sure to pre‑cut and sand parts 9 ‑ 12. These 4 components are required to fully assemble the go‑kart steering rack.
Note the part 12 orientation – the gear teeth should point in the same direction. Bracket PLYWOOD SHEET 2 4. Secure part 12 to the assembly using screws. ‒ Use 2 screws. ‒ Total of 2 locations. PlyFly Go‑Kart Instruction Guide • 2015 Release...
Fixed Steering Column Assembly Introduction Before beginning this assembly, be sure to pre‑cut and sand parts 13 ‑ 18. These 6 components are required to fully assemble the go-kart fixed steering column.
Assembling the steering column Required wooden parts DESCRIPTION REFERENCE INSTRUCTIONS 1. Press t ee nuts into parts 15 & 18 Note the orientation of part 15. Part 13 Steering Column Left PLYWOOD SHEET 1 Note the orientation of part 18. Part 14 2.
Steering Spindle Assemblies Introduction Before beginning this assembly, be sure to chisel out and sand parts 1‑8. These 8 components are required to fully assemble 2 steering spindle. Each assembly contains 4 parts.
Assembling the left & right steering spindles INSTRUCTIONS 1. Press bushings into parts 1‑2, 5‑6, & 7‑8 7. Using a mallet, cap the parts 1, 3, 5 with part 7. 8. Using a mallet, cap the parts 2, 4, 6 with part 8. Note the orientation of part 1 &...
Pedal Assemblies Introduction Before beginning this assembly, be sure to chisel out and sand parts 34 ‑ 39. These 6 components are required to fully assemble the go‑kart gas and brake pedals. Each assembly contains 3 parts.
Note part location and orientation of parts 36-37. Be sure to square the parts. 5. Secure parts 35, 38 & 39 using screws. ‒ Use 2 screws per part & per side. ‒ Total of 4 locations, 4 screws. PlyFly Go‑Kart Instruction Guide • 2015 Release...
Frame Assembly Introduction Before beginning this assembly, be sure to chisel out and sand parts 40‑55. These 11 components and assemblies1‑3 are required to fully assemble the go‑kart frame.
Assembling the frame INSTRUCTIONS 1. To begin this assembly 5. Press the large tee nuts into ‒ Start at Step 2 if you have a ‒ Part 42‑43 SINGLE WHEEL KIT ‒ Start at Step 4 if you have a ‒...
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Note the letter L should face part 41, away from the centerline of the go-kart. ‒ Total 4 locations 15. Test the drawer slide fit by moving the slide back and forth. ‒ Be sure there are no interferences between any screw head and the slide. PlyFly Go‑Kart Instruction Guide • 2015 Release...
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20. Repeat steps 18 and 19 using 25. Secure part 44 to the assembly using screws. ‒ Part 42 ‒ There is a purposeful gap in alignment to allow part 51 to sit flush with the assembly. ‒ Part 43 ‒...
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37. Install the 3 mounted bearings Note the orientation, location and position of each mounted bearing. 33. Secure part 52 using screws. ‒ Use 2 screws. ‒ Total of 2 locations. PlyFly Go‑Kart Instruction Guide • 2015 Release...
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38. Using a mallet, tap part 51 into place. 39. Secure part 51 to the assembly using 21 screws. ‒ Total of 21 locations, 21 screws. 40. Flip assembly right side up. 41. Lay part 50, with the small tee nuts facing upwards, into place.
Putting the go-kart together Introduction Before beginning this final assembly, be sure to have assemblies 1‑7 completed. These 8 assemblies are required to fully assemble the go‑kart. This chapter contains 10 individual procedural parts to successfully complete the full go‑kart assembly.
42. Note the drive shaft extends equal distances on both sides of the assembly. 9. Ensure all the hardware on mounted bearings are fully tightened PlyFly Go‑Kart Instruction Guide • 2015 Release...
Part 2 Install the brake caliper Chapter 10 The brakes will initially be installed and then adjusted. INSTRUCTIONS 1. Insert the socket head cap screws with an oversized flat washer through the holes located on part 43, P ART ‒ Use 1 socket head cap screw with 1 oversized flat washers per location.
Part 4 Install the steering spindles Chapter 10 INSTRUCTIONS 1. Slide the steering rack all the way to the right. 7 with the bolt facing out. 2. Insert P ART 7 are completely seated ‒ Check that the bushings on before installing.
Parts 35, 38‑39 5. Using a hammer, tap into place. 6. Test the alignment of each pedal assembly. ‒ Each pedal should be able to move freely and independently (some drag is expected). PlyFly Go‑Kart Instruction Guide • 2015 Release...
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Reference Assemblies Chapter 10 DESCRIPTION REFERENCE P ART Fixed steering column Assembly Recommended tools PARTS 13‑18 DESCRIPTION REFERENCE Needle Nose Pliers Gas Pedal Assembly Parts 34, 36‑37 Allen Wrench Brake Pedal Assembly Socket Wrench Parts 35, 38‑39 Required Assemblies Frame Assembly №...
‒ through the hole located on the left side of part 17. Note the location and direction of the red cable. Be sure to seat the red cable in the notches located on part 19 of PlyFly Go‑Kart Instruction Guide • 2015 Release...
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6. Continue to run green cable on the right side of 11. Feed the brake control cable through a washer into the the go‑kart fitting located on the brake. ‒ Through the cable ties located on Note path of the brake control cable through the brake caliper. ‒...
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1/16” D, throttle & brake control cable Parts 34, 36‑37 PN 12525 1 Throttle cable clamp PN 12537 1 Extension Spring Black‑Oxide, Precision PN 12560 Frame Assembly 1 Throttle Return Clip PARTS 21‑28 4.0 HP MODEL PN 12561 PlyFly Go‑Kart Instruction Guide • 2015 Release...
Part 7 Install the engine and drive train Required hardware The engine arrives with no oil, no configuration is required. № DESCRIPTION REFERENCE INSTRUCTION 8 Sheetmetal Screw Galvanized, #6 1. Stand the engine on part 50 located on PN 12551 aligning the engine mounting holes to the tee nut pattern (installed previously) appropriate for the engine model.
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‒ Be sure to align the keyway on the clutch with the keyway on the drive shaft. Note the orientation of clutch; the small sprocket should face the engine. PlyFly Go‑Kart Instruction Guide • 2015 Release...
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11. Insert 1/2” clutch key through the center of the clutch. 15. Connect the chain by sliding the posts of the master link into the holes located at the ends of the chain. 12. Using an Allen wrench tighten the set screws. Note the order of the assembled hardware.
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25. Thread the green cable into the right side of the engine. 28. Install the extension spring, by hooking one end to the Note the location of the green cable. hole located on the throttle linkage. Note the location of the extension spring. PlyFly Go‑Kart Instruction Guide • 2015 Release...
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29. Using pliers, hook the other end of the extension spring to 32. Continue to feed the throttle control cable all the way the throttle return clip. through to Note the location of the extension spring. Note the location of the throttle control cable. 33.
16. Secure the axle to the driven wheel using the shaft collar. 12593 SINGLE WHEEL KIT ‒ Use a socket wrench to tighten the locknut; while holding the locknut on alternate side with wrench. 3/16” square, 1”L PN 12539 PlyFly Go‑Kart Instruction Guide • 2015 Release...
41 located on the right side of the go‑kart. 12542 6. Insert the flag through holes located on the back right side of Seat Assembly and the go‑kart frame. Flag Note the location of the flag holes. Plyfly flag 12535 Required assemblies DESCRIPTION REFERENCE Seat Assembly PARTS 22‑33...
‒ Use 6 screws. unfinished side is facing outward and ready to receive paint). For more information on Visual reference of the plywood sheets, see page 61. ‒ Total of 6 locations FINISHED!! TIME TO RIDE!! PlyFly Go‑Kart Instruction Guide • 2015 Release...
Note If you received a 1/4” plywood sheet that is finished on one side and you intend to paint the Plyfly go-kart seat or fairings; reverse wooden parts 28-33 and parts 53-55 (so the unfinished side is outward facing and ready to receive paint).
List of the wooden parts List of the wooden parts reference image reference image DESCRIPTION DESCRIPTION Part 1 Part 9 Steering Spindle Outer Spacer Steering rack Bracket PLYWOOD SHEET 1 PLYWOOD SHEET 1 Part 2 Part 10 Steering Spindle Outer Spacer Steering rack Bracket PLYWOOD SHEET 2 PLYWOOD SHEET 1...
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Part 31 Seat Side Right Seat Thigh Bolster Right ‒ gas tank side PLYWOOD SHEET 4 PLYWOOD SHEET 3 Part 24 Part 32 Seat Crossbar Seat Back PLYWOOD SHEET 1 PLYWOOD SHEET 4 PlyFly Go‑Kart Instruction Guide • 2015 Release...
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List of the wooden parts List of the wooden parts reference image reference image DESCRIPTION DESCRIPTION Part 41 Frame Rail Inner Right Part 33 PLYWOOD SHEET 1 Seat Bottom PLYWOOD SHEET 4 Part 42 Frame Rail Outer Left Part 34 PLYWOOD SHEET 1 Brake Pedal PLYWOOD SHEET 1...
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Floor Panel PLYWOOD SHEET 4 Part 52 Frame Gusset PLYWOOD SHEET 2 Part 53 Fairing Left PLYWOOD SHEET 4 Part 54 Fairing Right PLYWOOD SHEET 4 Part 55 Fairing Front PLYWOOD SHEET 4 PlyFly Go‑Kart Instruction Guide • 2015 Release...
Note If you received a 1/4” plywood sheet that is finished on one side and you intend to paint the Plyfly go-kart seat or fairings; reverse wooden parts 28-33 and parts 53-55 (so the unfinished side is outward facing and ready to receive paint). For a complete list of wooden parts, go to “List of the wooden parts”...
Dead blow Hammer Metric Allen Wrench or mallet included with mounted bearing Sandpaper Socket Wrench Orbital Sander Wrench (optional) Jigsaw or Needle Nose Pliers Reciprocating Saw (optional) Electric Driver Impact Driver (optional) PlyFly Go‑Kart Instruction Guide • 2015 Release...
List of loose contents 2.5 HP 4.0 HP 4.0 HP 4.0 HP 4.0 HP SINGLE WHEEL SINGLE WHEEL SINGLE WHEEL LIVE AXLE LIVE AXLE № KIT DESCRIPTION 10” WHEELS 10” WHEELS 12” WHEELS 10” WHEELS 12” WHEELS Clutch 12576 #35 Chain, 11 Tooth Pulley for 5/8” D ―...
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10” D Wheels 12591 ― ― Undriven wheel 12” D Wheels 12592 ― ― ― Rear driven wheel 12” D Wheels 12593 ― ― ― Undriven wheel Flatworks Flag 12535 Plyfly safety flag PlyFly Go‑Kart Instruction Guide • 2015 Release...
List of the packaged contents 2.5 HP 4.0 HP 4.0 HP 4.0 HP 4.0 HP SINGLE WHEEL SINGLE WHEEL SINGLE WHEEL LIVE AXLE LIVE AXLE № KIT DESCRIPTION 10” WHEELS 10” WHEELS 12” WHEELS 10” WHEELS 12” WHEELS Large Metal Bushing 12504 Flanged, 3/4”...
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3/16”, 1/2” L Throttle Return Clip 12561 ― 4.0 HP MODEL Button Head Cap Screw 12562 ― 5/16”‑24, 3/4” L Set Screw 12563 Clutch Pan head 12564 M6, 12 mm L ― 4.0 HP MODEL PlyFly Go‑Kart Instruction Guide • 2015 Release...
(all collectively hereinafter referred to as “I” or “me” or “my”, In the event of a medical emergency, I hereby authorize Flatworks and as the case may be), in consideration of being permitted to use and...
RISK AND RELEASES), WAIVERS, INDEMNIFICATION PROVISIONS, malfunction from whatever cause, or any other negligence or fault of Flatworks, User, for himself or herself, and for anyone acting on his or her LIMITATIONS OF LIABILITY, LIMITED WARRANTIES, A COVENANT NOT behalf, further agree to hold harmless, defend, and indemnify Flatworks...
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Do you have a question about the plyfly and is the answer not in the manual?
Questions and answers