Build a DIY go-kart from plywood

Clear a large space outside and put down your drop sheet, then prop up your sheet of treated plywood so it’s lying flat. Decant Resene Quick Dry primer into a paint tray and use a roller to apply the primer in long sweeping strokes. Once one side is dry, flip it over and do the other.

Use a circular saw to cut your 1200mm length of timber into pieces for your axles, one to 500mm and the other to 600mm. Give them a good sand with an orbital sander to tidy up the surfaces. Use a grinder to cut the 1000mm x 16mm galvanised rods and then attach them to the blocks of wood using steel saddles.

When the primer is dry, use a pencil and mark out your pieces for the go-kart body with a pencil. Move the blade on the circular saw to get the 7/20 angle cuts, as this will help the piece fit together more easily when you go to assemble. Then use a jigsaw to cut the arcs for the cockpit. Give all your edges a sand with 120 grit sandpaper and wipe away the sanding dust.

Place the base of the go-kart on the front axle block and drill a hole for the steering bolt, using a 16mm drill bit. Attach all the front axle fittings and make sure it can turn both ways with ease.

Use your drill and exterior screws to attach the pieces together, forming a snug spot to sit. They should fit together like a puzzle.

Pour some Resene Enamacryl into a paint tray. Doing this ensures you won’t be transferring any contaminants that may be in your rollers or brush into the main paint can. Using a PAL 100mm Easy Reach roller will make the job much quicker. Wait for the paint to dry, then apply another coat.

Top tip: If your kids like sleek and shiny, you can amp up the bling factor with Resene FX Metallic as your topcoat.

Once the second coat is dry, attach the wheels to either end of the back axle and screw it into the back platform area.

Attach wheels to front axle as well.

Secure your two eyelet screws on either side of the front axle and loop the rope through each side, tying it off at each end. This will create your handle and make it easy to steer.

To make your double stripes, apply three strips of painter’s tape down the side to use it as a stencil. Place a bowl at the centre and draw around it with a pencil to create the circle shape, then cut around with a craft knife.  Then paint your lighter colour – Sean has used Resene Enamacryl gloss waterborne enamel in the colour Resene Black White along the lines and very carefully within the lines of the pencil circle. Once it’s dry, remove the tape and paint in your lucky number in the centre of the circle.

This is a great project to do over a spring or summer weekend when you have some spare time and the kids will be able to enjoy your handiwork for years to come.