g2 build

[ccmoto286]

started with a g2 i got for free. put a 6 inch lift in.

[ccmoto286]

stripped old paint, primed, painted black. it was my first time painting anything with a spray gun and it didnt turn out the best. later decided to go with white.

[ccmoto286]

bought the motor for pretty cheap. he showed me that it ran before i took it home. once i pulled it apart to remove the govenor i noticed a lot of rust and corrosion in the motor and pitting in one cylinder. the motor must have been outside with one spark plugged removed. had to have the cylinders bored, got the rust off the crank and cam, and cut down the crank and re tapped. installed the high rev kit. fabricated my own engine cradle. after all that, had it running for a few days and all of the sudden it died. tore the motor down and one piston rod had seized to the crank and broke in half putting a hole in the case. jb welded the case, cleaned everything really good, put new rods in and it has ran perfect ever since. i think either i torqued the rods wrong, or had metal shavings in the oil holes that eventually came out between the rod and the crank.

[ccmoto286]

got the motor mounted and just ran a straight pipe for exhaust at first. finally rigged a little better exhaust system with a muffler. the muffler broke off 2 times before i finally decided to make a bracket. some day i will spend more time on a nice exhaust system. i also set the motor up to run all the time instead of starting and stopping with the gas pedal.

[ccmoto286]

i bought some seat covers on ebay. i didnt have the seat backs for my cart. i liked the way the ezgo seat back was so i ordered the foam and cover for an ezgo, and ordered the seat bottom cover for a g2. cut new plywood for the bottom and used the old foam. traced the seat back foam on a piece of plywood, cut it out, stapled the cover on, and covered the back with a piece of black sheet metal. also bought some fog/driving lights from walmart and mounted those.

[ccmoto286]

built a roll cage out of 1.5" tubing. bent the back rails with a pipe bender from northern tool. those bends are about as far as the pipe bender will do before it kinks the tubing. welded nuts on the front sides of the front tubes and bolted through the frame from inside the wheel wells. welded pieces of smaller tubing (about 3" tall) onto the frame behind the seat that the bigger tubing on the cage slides onto so it can be removed if i want. also made a dash out of 1/8 aluminum plate, painted the steering stem and seat handles, and installed a new steering wheel.

[ccmoto286]

bought an atv plow off craigslist. modified the plow mounts that came with the plow and welded them to the frame. mounted a 2000lb super winch from ebay to raise and lower the plow and i put some chains from denniskirk on the tires. it actually works really good. wouldnt hurt to have some weight on the rear though.

[csason]

very nice, bet it beats shoveling.

[ccmoto286]

yep, a lot more fun and easier than shoveling. it pushes really good with the chains on the tires but still thinking about welding the rearend someday.

[TheNewGuy]

Nice set-up!