roughly 8 years old. It's a dual-purpose project: learn welding/fabrication skills and acquire cheap fun for kids. No competition involved, just backyard turf terror. Let's build it on paper. Frame tube size? Engine make/model? Clutch and wheel sourcing?
Step 1: find a free or cheap riding lawnmower and use it as a donor
Find a pile of 3/4" pipe.
Harbor freight predator engines are a good choice.
I think id buy an old go-kart that needed work and resto-mod it.
Maybe start from scratch after you're finished so you'll have an idea of what you want it to do better etc.
If your welding skills are questionable this may not be a good place to experiment. Yard karts can be found cheap.
There is no better time to learn to weld then after having just bought a pile of tubes and a welder. Obviously, initial learning of the basics wouldn't actually be done on the chassis itself. But cuts from the same pile of tubes that will be used to make the chassis, also make for the perfect practice medium. Consider that a large percentage of Locosts have been, and will continue to be, their builders first major welding project. Although I also found that a great 'starter' project to precede that, is welding together a cart for your welder.
I would probably build very similarly to an SAE Mini-Baja. Then use an adjustable stop on the throttle pedal to restrict it down as necessary...That way it can grow with her, as well as having the ability to be fun for the whole family. Although that also might be a bit overkill for what you were thinking.
My six year old girl is getting a 70s vintage yard kart with a tiller motor. The fab im doung is impact absorbing bumpers and a moderate roll cage (wife's mandate).
The pile of tubing is getting saved for a fully articulated trail cart for the uwharrie off road trails.
Sae mini baja? Tell me more please.
Didn't the same guy who wrote the locost book write a cart one? Might be a good place to start.
Otherwise, an old Snapper rear engine mower has almost everything you need after you swap out one of the sprockets to speed it up.
1 inch dia 120 wall tubing. HF motor, other parts from http://www.azusaeng.com/ and http://www.gokartsupply.com/steering.htm
Start with a zx14r. Take off and sell everything that isn't motor. Use that to fund tubes. Go from there.
In reply to mndsm:
That'd be a serious dad kart. I however would not put one of my offspring into a machine that I LEARNED to weld on. Unless you're one of the exceptional Humans that does not feel regret for your actions.
Appleseed wrote: In reply to mndsm:
If it was my child, I would be serious, and only realize the gravity of my mistake the first time I test drove it and caught a triple digit speeding ticket. In reality, joking.
OldOpelGuy is correct: Build your own off-road buggy on Amazon. (I found a copy on a remainder table once and couldn't resist.) IIRC, his daughter wanted pink. Very pink.
Dusterbd13 wrote: My six year old girl is getting a 70s vintage yard kart with a tiller motor.
+1 to this. Hard to beat the simplicity and look of a vintage (or vintage styled, because of $$$$$) cart. When I finally have a garage someday, I will be picking up one of these for my son and I to play with. 
Trackmouse wrote: Unless you're one of the exceptional Humans that does not feel regret for your actions.
LOL...Melodramatic much?
In reply to Driven5:
Kinda joking. Kinda.
Inspiration: http://www.pirate4x4.com/forum/general-4x4-discussion/633445-honda-powered-kid-buggy.html
Dusterbd13 wrote: Sae mini baja? Tell me more please.
Collegiate competition. With a 10HP Briggs & Stratton engine and CVT, they're not exactly fast. I think they tend to top out around 35mph, and don't have crazy acceleration either. But are built to tackle all manner of difficult terrain though. Beyond the typical 4 hour endurance of dirt, mud, ruts, bumps, and jumps...Other challenges can include things like pulling, rock crawling, mud bogging, and even amphibious capabilities. A good rule set to use as the basis for a design, with the finished rigs being a good place to look for ideas and inspiration.
Bumpy SAE Mini-Baja ride along.
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In reply to Trackmouse:
If you're that concerned about weld quality, you'll also want to inspect all of the welds on any production vehicles you let your offspring ride in...Especially older ones. From British Leyland to Ferrari, the automotive industry has a considerable history of less than impressive weld quality. No joke.
In your experience, what makes a tubular steel chassis so unsuitable of a first project after learning how to make demonstrated structurally sound steel tube weld joints.
Harbor Freight Predator 212 engine ~ 6.5 hp ($100 with coupon). Max Torque Clutch, 12 tooth ($80). With a 65 tooth sprocket ($15), speed should be a max of 25-30 with the governor in place. Check out www.diygokarts.com
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