RZR "S" 800 engine in an 1984 EZ-GO Marathon

[EZGO 89 RED]

Finally got the golf cart back into the shop. I've been waiting for a while now.

I am getting the front suspension figured out and will hopefully have that done by next Friday, not including the steering I have to figure that out still.

Here's a picture with a mock fit-up of the front suspension

[EZGO 89 RED]

I got the front all welded in, pics to come on monday.

I have to machine my steering shaft still should take a day or two.

I probably am going to have to get stiffer shocks for the front, b/c I put them on their hardest setting and its still to soft in my opinion.

I will be starting the rear-end this coming week and it will be similar to
"98 TUNNER"'s build here: http://www.buggiesgonewild.com/membe...ject-cart.html

[98 TUNNER]

Looks like your getting there. Thanks for the mention. Unfortunately have not finished mine yet. *** life just keeps getting in the way keep up the good work.

[AirJunky]

Badass build you have goin on. Lots of potential here.

[EZGO 89 RED]

Pics!

Front welded in without tires



Front welded in with tires (front view)



Front welded in with tires (angle view)



Bottom supports, I used a couple of pieces of angle iron



Top supports, I used four pieces of 1" square tubing



Steering shaft partially completed, 3/4" round stock machined down on one end to about 0.670", and a 3/4" washer welded on.





Placement of the shaft




Hope to finish the steering shaft by the end of the week, I need to make and weld on the top and bottom arms to it, as well as make the top support.

[EZGO 89 RED]

I am going to stop working on the steering for a while, b/c its taking too much time away from me installing the rear components.

I will come back to the steering later, the problem is the there is not enough travel in the steering column now that the shaft is farther away from the golf carts steering gear box.

Anyone else have this problem when installing an atv front end into your cart?

I am hoping that a pair of 25" tires would still have clearance in the front, but i will have to check wether or not it will. I definitely need a pair of stiffer springs in the front, right now they're on the hardest setting and the cart still sinks too much to the point that it leans toward the side that I'm sitting on.

I have about 23 more school days in my schools metal shop to finish the cart, so i have to really get going and install the rear end suspension/drive and the motor.

[JcXtreme72]

I love this thing. Can't wait to see it go. I'm dropping a Polaris engine in a Yammy G2. Mine is a 400cc 2 stroke out of a sport quad. I got the big bore kit and had it ported and polished with reeds. Engine shop dyno'd it over 80hp. I'm also using quad front suspension but something a little more custom in the rear so it can jump in the sand all day with out fear.

[EZGO 89 RED]

Nice

That things gonna go at 80hp

[EZGO 89 RED]

I solved my issue of steering I think. I am going to use the golf carts steering shaft, and then make an adapter to attach the heim joints of the atv suspension to the shaft. This will give me the needed smaller turning radius now that the link that the golf cart steering wheel turns is closer to the shaft than before.

With the old system that I tried making, it would have had about a 25 foot radius.

[andyww16]

very cool build i like it!
I used the same front end as you did mine was off from a warrior. I swaped the original shocks to yz450 shocks with remote resevoirs handling became alot stiffer and better.
But looks like your doing awsome