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Old 08-17-2021, 06:06 PM   #1
smackley
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Default Smackley's G1 restomod, plus big block 440cc

I had this ratty old G1 sitting in my backyard, but I had always wanted to do some sort of restomod. The body styling was so retro cool. I had no clue how bad the condition was, until I started disassembly. I almost trashed it several times, but it's starting to take shape and I'm way too far invested at this point to give up...


So much rust though!
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Old 08-17-2021, 06:13 PM   #2
smackley
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Default Re: Smackley's G1 restomod, plus big block 440cc

After breaking it down, I saw it had some really bad rust areas needing to be carved out and have new stock welded back...

Once the main stuff was reinforced, I hit the whole chassis with some POR15 to seal it back up.
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Old 08-17-2021, 06:21 PM   #3
smackley
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Default Re: Smackley's G1 restomod, plus big block 440cc

The G1 is a 2 stroke, and I wanted a reverse gear, so thankfully Skoal82 had a rearend from an old G2 chassis lying around. The rear axles on the g2 are not symmetrical like the G1 and would have had some bad interference forced into the differential and chassis. I had to remove the axle carriers from the G1 rear end, cut them with the axles out, and them rotate/weld them into a good orientation for the differential. Not too hard but just another thing to do on the long list, that keeps growing.
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Old 08-17-2021, 06:25 PM   #4
smackley
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Default Re: Smackley's G1 restomod, plus big block 440cc

Rearend, axles, hubs, new brake shoes, new brake lines, new return springs, and new rubber all mounted finally. Pheww, that was a lot of sweat for what seems like little progress. Diff got some fresh gear oil, and steering box as well.

New floor boards and battery tray steel as well. It finally rolls again...forward AND backwards!
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Old 08-17-2021, 06:29 PM   #5
smackley
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Default Re: Smackley's G1 restomod, plus big block 440cc

The body was also in rough shape, but thankfully the rear is made of fiberglass. The front took some fiberglass work as well, and I'm not sure the longevity of a resin over plastic bond but time will tell. I'm no bodywork expert but I couldn't leave it alone.
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Old 08-17-2021, 07:20 PM   #6
TheNewGuy
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Default Re: Smackley's G1 restomod, plus big block 440cc

Lookin good so far.

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Old 08-17-2021, 07:22 PM   #7
smackley
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Default Re: Smackley's G1 restomod, plus big block 440cc

I got some inspiration for a paint theme and got to work on the body. Oh, and I got a new 440cc too!
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Old 08-17-2021, 07:25 PM   #8
smackley
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Default Re: Smackley's G1 restomod, plus big block 440cc

Paint scheme getting further along. Loving the basket. And general retro vibe.
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Old 08-17-2021, 07:56 PM   #9
raydhd
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Default Re: Smackley's G1 restomod, plus big block 440cc

Nice inspiration
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Old 08-17-2021, 09:52 PM   #10
slonomo
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Default Re: Smackley's G1 restomod, plus big block 440cc

Looks really nice! I've always loved the G1, tough carts. I miss mine. Maybe I'll get another someday. You'll like the 440 compared to a stock engine.
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