Not you average Golf Cart

rmack898

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Ok so this project has been on my back burner for almost 2 years. I straightened up the yard yesterday and decided that since I had some open floor space in the shop, it was time to bring this project to the top of the list.

I'm starting out with an older Yamaha G16 golf cart that has no engine. I have a set of new rolling stock from a Suzuki King Quad, and a brand new 18HP Yanmar 3 cylinder diesel engine. This won't be a quick project and weeks may turn into months but I would like to have it finished before July so bear with me as it might take me a little while to get it all done.

After staring at all the parts for a little while I am starting to formulate a plan. First off I will have to modify the axle flanges and spindles to accommodate the bolt pattern for the ATV wheels as well as a way to compensate for the change in offset.
I'll need to design and fabricate a suspension lift and possibly a body lift to allow for the taller rolling stock.
The engine is quite tall and I'll have to figure a way to make it fit in the space under the seat. I'll also have to find a place to mount a radiator and electric fan along with all the associated piping to keep the engine cool. Electrical system, fuel system, clutch, the list keeps getting longer the more I think about it.

It should be a fun project and I should have a pretty unique and cool cart when its done. Feel free to make suggestions along the way, it's good to have another set of eyes to see things from a different angle.

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that looks like a cool project. first, the diesel is only high because the oil pan is on the bottom. could a fella mount the engine at an angle and make the oil sump in a different place ? reminds me of a slant six molar of the day. . . . just thinking outside the box.
then again, maybe a "cab-over" design to put the seat right over the front wheels. . . . again, outside the box. they would be really fun to play designer with . .
 
Thinking if you have raise it for the new tires make the rise between frame and body this will give more room for the engine. also you cold put a grill on the front and add the radiator up there . Seems you would get better air flow. Mark
 
mount the engine at an angle and make the oil sump in a different place ?

The flywheel extends almost to the bottom of the oil pan. Once I get the dirt cleaned out of the engine compartment, I'll take some measurements and see exactly how much I have or don't have.

also you cold put a grill on the front and add the radiator up there . Seems you would get better air flow. Mark

That will be my first choice.

any color scheme thoughts yet?

Nothing in mind as of yet other than it will be BRIGHT.


No time in the shop tonight but I should get a few things done tomorrow.
 
might be a good application for a stretch............

I might have to stretch the front end out to get clearance for the new tires but I'll wait till I have them all mounted before I go there.

So here is what I know. I have 20.5" of vertical clearance in the engine compartment and the engine is 19.5", it's tight but it will fit.

The wheel bolt pattern is different as well as the back spacing. The old bolt pattern is 4X3-5/16 and the new bolt pattern is 4X4-5/16. In addition to the different bolt pattern the new wheels have 3" of additional back spacing that I have to make allowance for. 3" wheel spacers is just way too much so I am opting to make new hubs for the spindles with the new bolt pattern and the additional 3" of back space. The original front hubs are cast aluminum and look pretty weak. I'm making new 2-piece hubs from steel. This is a low budget project and I really don't want to spend any money on it so I'm going to use as much material as I have on hand to make it all work.

I had a slug of round stock that was 5-13/16" in diameter so I cut off 2 pieces 3/4" thick in the band saw, these will be the flanges for the new front hubs. I have some 3" round stock to make the bearing carrier part of the hubs from but the OD needs to be 2-1/4" and I don't want to have to turn them down that far so I will look for some sch 80 pipe at work tomorrow and see if it has enough meat in the wall thickness to work for me.

The previous owner of this cart started to make a 4' lift for it and it looks like is a sound design and maintains the factory steering geometry with the exception of the pitman arm, so I will go with it for now and see if I need to make changes after I have a rolling chassis.

I'll continue with making the hubs and getting the new wheels mounted and have a rolling chassis before I move forward with the engine install.
Stay tuned.

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4' risers you should have plenty room for tires and engine. ha! ha!
 
Well I was able to spend a few hours in the shop today and I made some progress but I may have found a new obstacle, I'm not sure yet. Here's what I got done.

I drilled the new bolt pattern for the wheels in the flanges. I counter bored the backside of the flange so that when I press in the wheel studs they will be flush and also long enough to mount the new wheels.


I was looking for some 2" sch. 160 pipe to make the bearing carriers from but pipe that heavy is non-existent where I live so I made the bearing carriers out of 2-1/4" solid round stock. I had to step drill the 4" long stock up to the biggest drill I had which was 1-1/4" and bore it the rest of the way. There are 4 different inside diameters over a 4" length and I had to do come creative fixturing with a 2" dial indicator to get the depths right.


Once the flanges and carriers were done, I welded them together. I installed the bearings and put the new hubs on the spindles. I re-used all of the old bearings and seals. I mounted the new wheels and this is where I think I may have a problem. The hubs turned out great and the wheels spin just fine, but I may have an interference problem with the steering. The 4" lift seems like it is more than adequate but I may have to stretch the whole front suspension forward about 2" to give steering clearance when the suspension is at full compression. It was a long day and I was beat so I'll take a closer look at what needs to be done on Monday.

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