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Make a Billy Kart With Only 3 Power Tools

 

Get your kids outdoors and join them for the fun with this DIY Billy Kart project from the team here at Worx Tools. Whether you call it a Go Kart or Billy Kart it’s a stack of fun for the kids (and when made sturdily enough is awesome for the adults too :)

You can complete the Billy Kart with just three Worx Tools in less than two hours! That’s a Sunday project for the family with time to spare to test out your new ride.

Worx 20V H3 Drill // Worx 20V Sonicrafter // Worx 20V WorxSaw

Step 1: Measurements
Using the pine board mark out the nose of the cart. You can use a bowl or one of the tyres to trace the curved nose. Measure from the tip of the nose 1150mm and mark for cutting. With the rest of the pine board, measure 4x at 300mm and measure 1x at 460mm. With the piece of hardwood now measure 4x at 440mm and 1x at 490mm.

Step 3: Sanding
Using the Worx 20V Sonicrafter with the sanding head, sand the nose of the cart until it’s a smooth semicircle. Make sure to sand all cut edges.


Step 4: Making the Seat
Lay out the 1150mm cut piece of pine with two of the 300mm pieces of pine on either side flush with the blunt end. From there it’s time to lay out the supports. Place two of the 440mm hardwood pieces across the three pieces of pine. Place one in the middle and one on the end closest to the curved nose. With the 490mm piece of hardwood place that flush with the back with 25mm overhanging each side. This will be used for the back axle. Using the Worx H3 drill with a Phillips head, screw the hardwood pieces with the 30mm countersunk screws to the three pieces of pine.

Step 5: Seat Walls
To make the walls of the seat you will use the last three pieces on the pine that you’ve cut. Using the Worx H3 Drill again you will screw the last two 440mm of pine to both sides of the seat. You will want to be screwing the walls into the sides of the seat bottom. This step will take some precision so move at a level you’re confident with. After putting on both sides it is time to put on the back. The 460mm piece of pine will be flush with the ends of the sidewalls. Screw into both the seat base and the sidewalls.

Step 6: Steering.
Now it’s time to create the steering. Using one of the pieces of the 440mm hardwood pieces find the centre of the board. Measure in 220mm from the end and 33mm from the side and mark with your pencil. On the nose of the pine board also mark in 70mm from the nose and 70mm from the side with your pencil. Using the Worx H3 Drill with a 8mm drill bit, drill through the hardwood and pine in the centre where you’ve marked. Put the bolt through both boards with the hardwood on the bottom and tighten with the nut until snug. Don’t over-tighten so it can move, this is your steering.

Step 7: Axles
Now it’s time to attach the the axles. On the bottom of the hardwood steering board using the Worx H3 Drill, screw in the brackets for the axle on either end. On the back piece of the hardwood under the seat you can attach the back axle with the brackets on either end.

Step 8: Foot Rest
With the tape measure mark 470mm back from the nose on the pine board with your pencil. Using the last piece of 440mm hardwood, place where you’ve marked on the pine and attach using 4x 30mm countersunk screws with Worx H3 Drill.

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Step 9: Steering Rope
Time to finish it off with the steering rope. Measure in 2cm from the end of the front piece of 440mm hardwood with the front axle and mark it with your pencil. Using the Worx H3 Drill and the 8mm Drill bit, drill holes on both sides. From there feed the rope up one hole and down the other. Tie a figure 8 knot on both ends of the rope and pull tight.

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Supplies

– 140mm x 19mm @ 2.4M pine
– 66mm x 19mm @2.4M hardwood
– 30mm Countersunk Screws
– 65mm M8 Nut & Bolt
– 4 Wheels
– 2 Axles and Brackets (package at Bunnings)
– Rope 2M

Tools

– Safety glasses
– Hearing protection
Worx 20V H3 Drill
Worx 20V Sonicrafter
Worx 20V WorxSaw
– Square
– Pencil
– Clamps
– Drill Bits
– Driver Bits

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