Hi,
Not sure if this will help, although it might be worth considering. The U.K. MSA cadet karts wheel base has to meet the homogation rules. I believe it is 925cm-950cm, not sure though.
Different chassis will have the seat mounts in different locations and could offer more room. Recently a taller cadet that I know whom races a zip storm, tried a BRM and it had more room.
The Shark chassis (not made anymore) had adjustable seat stays, that would allow you to get the seat further back.
Although the height issue, would disadvantage in other ways, handling might be compromised with seat in the wrong position. Weight is also going to be an issue as he grows and I think he would struggle to make the weight at 5.4 anyway.
Other ideas: Custom pedals, adjust seat stays etc.
No easy answer....
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