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ALL you have to do is SUCK your own DICK. haha
The engine probably failed you might as well got to silver-streak-gokart-engine-american-sportworks.aspx they have a kit to replace the defective engine.
3/4 inch steel pipe if making a strong double layer frame.
Russell Markert created them after the John Tiller Girls.
Depends on what needs to be fixed. Could be $50 or could be $1000. If its a couple of average fixes I would say around $300