How to Make Installing Kart Side Guards Safer and Faster (With a Little Trick)

Like many “garage” kart drivers, I too belong to that category of people who, in order to get on the track, have to become half mechanic and half Tetris master. Before setting off, I have to dismantle half the kart and fit everything together like a 3D puzzle, because there's never enough space.

My transport vehicle? A Volkswagen Caddy, kindly lent to me by my girlfriend's dad. A reliable van, yes, but one that forces me to become a loading artist in order to get the karts, tools, tires, fuel cans, and even my patience to the track.

Nut completely worn out due to

The first step was to remove the side guards. Here I noticed something quite important: the screws that secure them to the frame are quite damaged due to constant rubbing against the asphalt. In these conditions, the nut becomes difficult to unscrew because the wrench tends to slip without being able to grip properly.

In addition to the practical problem of disassembly, there is also a safety issue: a nut that is so worn could get stuck between the cracks in the curbs, compromising the stability of the kart and creating potentially dangerous situations on the track.

Screw blocked by the radiator bracket

The bolt that wasted the most time was undoubtedly the one near the radiator. Its position is unfortunate: practically hidden behind the radiator bracket, which blocks it and makes access with the wrench a real nightmare.

Now, let's be clear: we are talking about a trivial operation such as removing a side guard, not overhauling an F1 engine. Yet, I wasted an eternity on a single bolt. The question arises: is there really no more practical and intelligent solution? A small design tweak could save many drivers (and improvised mechanics like me) from turning a routine job into a marathon of profanity.

Protection for the side guard mounting tubes

I therefore came up with an alternative solution. The main function remains the same—to secure the side guards to the frame—but I also tried to resolve the issues that had previously arisen.

The yellow component plays a key role: it protects the frame tubes. Its base is completely flat, and the material chosen is no coincidence. It is a polymer composed of carbonyl polyethylene reinforced with fiberglass. This combination ensures high resistance to abrasion and mechanical stress. Furthermore, thanks to its flexibility, in the event of an impact, the piece tends to bend without breaking into small fragments, thus increasing both durability and overall safety.

3D-printed carbon polyethylene disc with glass filler

Installation is simple and straightforward: just insert the component from below, with the M6 countersunk screw already positioned inside the hole, and secure it to the frame.

Assembly of the 3D printed disc

Then place it on top of the second piece, which already contains the nut. All you need is an Allen key to secure everything... et voilà, you're done! A much simpler and faster operation than the original system.

Kit installed correctly

What changes would you have made? Have you ever found yourself in similar situations, struggling with impossible bolts and parts that seem designed to complicate your life? Tell me about your experiences in the comments, share your tricks as true karters. I can't wait to read your stories and advice.

Federico Rodighiero.