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TKART magazine Under Review | Racer 401 RR, the latest evolution of the Tony Kart OK world champion
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03 April 2022
CIK-FIA 2022-2023

The Racer 401 RR chassis is certified with approval number 012-CH-30 for the 2022-2023 seasons. The CIK-FIA regulation change, however, provides that the new approvals last indefinitely as long as an annual fee is paid.


The chassis can be used in both single-speed and shifter classes. This article analyses the version intended for Direct Drive classes.

30 mm

The chassis are generally made using 30 or 32 mm tubes. The Tony Kart Racer 401 RR has a chassis with all 30 mm tubes.


There are two schools of thought that distinguish the welding of a chassis: by hand or robotic. The Tony Kart Racer 401 RR chassis is robot welded with a continuous arc technique with a fully automated process.


The standard accessories are in magnesium or ergal according to the type of use of the component: another factor that demonstrates the level of research and development that the Tony Kart chassis is based on. Choosing the right material for the specific component ensures maximum quality, performance and operational reliability.

It was 2004 when Tony Kart, the flagship brand of the OTK Kart Group manufacturer, launched the Racer model on the market. Probably not even the owner and founder of the company, Roberto Robazzi, at that time, could imagine that the Racer would become for Tony Kart what, in the automotive field, the 911 model represents for Porsche. But this is what happened, because a continuous development began with the Racer, through various versions during the various successive approvals, which led to winning 9 world titles, 3 of which in the last two years (in the OK class in 2020 and 2021, in the KZ class in 2021). The Racer thus became a real reference point not only in the Tony Kart range, but in the whole karting scene in which it succeeded in affirming itself also thanks to the basic philosophy that is at the base of every manufactured product: "Designed, Engineered , Manufactured 100% made in OTK". The concepts of automation and standardisation of production were introduced for the first time with the Racer, combined with levels and methods of quality control never seen before in the karting sector.

To tell the truth, the OTK Kart Group started on the path of production automation well before the development of the Racer, in other words in 1997, the year in which it introduced robotic welding for chassis. To this production approach the creation of a department dedicated to quality control (which focuses not only on the finished product, but on all the components in the various production phases, right from their raw state) was added and the introduction in the company of a research and development centre.
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Thanks to the continuous collaboration with the Tony Kart Racing Team racing department, The R&D department of OTK Kart Group plays a fundamental role not only in the design of new components and in the refinement of those already in use, ensuring greater performance and constancy of operation. but also in the choice of the right materials according to the type of use of the component.
In this regard it is interesting to emphasise how, despite one of the historical characteristics of Tony Kart chassis beig that of having a "full magnesium" component and accessory kit, the company has recently chosen to switch to high quality forged aluminium to make certain components such as the pedal set and bearing shells. All considerig the environmental impact generated by some phases of magnesium production and treatment, but also in relation to the excessive wear of some components, such as the axle bearing flanges. The difference between ergal and magnesium is important: the former gives better mechanical characteristics including greater resistance and less wear, while the latter has physical qualities such as lower specific weight and higher thermal conductivity, which is why it is used in components that need good heat dissipation like disc holders, gear wheel housings, rims and wheel hubs.
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