1991/1992 Club Car Carryall 2 Build

[Firefytr29wfd]

Been working on this project for a while now, been using this site as a MAJOR reference for ideas and how tos. Figured it is time to start a build thread. Picked up this Carryall 2 last fall to build a farm cart/hunting cart out of. The serial number says its a 1991 and it had the old KF82 engine in it. But all the body parts are 1992 (shifter in front, only bed tips/not whole body), my local dealer says it was probably a really late year 1991 build...

Old engine was wasted, and had access to a Honda GX610, and so it began...

How I got it


Old engine out along with ALL the factory wiring, built my own harness along the way.


New engine mounts built




Engine install for mockup, fuel tank cleaned and wiring started


Built a throttle linkage and used a push/pull style throttle cable




Fuel system finished up and electrical system almost done


Built a header and wrapped it






Future plans:
-Currently working on a muffler and exhaust (OE automotive muffler)
-Just ordered my clutches from CPP (O6 1" shaft clutch and Big Block Driven Clutch)
-6" Jakes A-Arm Lift Kit
-22" Aggressive Tires on Black steel wheels
-Front winch
-Electric actuator dump on bed

[Panhed66]

Looking good. Keep us posted and keep the pics coming. Very informative.

[Firefytr29wfd]

Finished up the muffler

Rear view, mounted using old mount from the factory exhaust welded to the muffler case


Top view


TEMPORARY piping ran, will have hard pipe bent up after lift kit is installed and final height set. Hoping to go under the crossmember.

[Firefytr29wfd]

Got my clutches from CPP installed over the weekend, the belt I bought is too short... Measured it up and have a belt on order for it.


Got my seat back cleaned up and installed, and got some marine plywood cut for a new seat bottom.

[vzdude]

Looking good! Wishing I had big blocked my Carryall II ! Would have had TONS more room for exhaust. Still trying to keep the plastic cool on my current project! Switched things up so I can close the gate on the truck when pulling the camper.....carryall was just too long.

[vzdude]

Also.....what size belt did you end up with? I think mine was 42 5/8 ? Got it from Tom at CPP. Says it's the longest one he had. It's still really snug. Would like one just a tad bit longer! Let me knowif you can, when you get it.

[Firefytr29wfd]

Belt I needed ended up being 45", had to order it from Advance Auto Parts. I measured the clutches at 43" (inside drive to outer driven +2").

[kimmer71]

I'm working on a similar build with the same clutch. I have a clearance issue where the clutch will hitting the shackle mount when the suspension compresses or articulates. I can't move the engine because of belt alignment issues. This Buggie already has a 6" lift and I don't really want to go any taller. The engine cradle has been dropped 2" in the front already. If I drop it another inch...I get roughly another inch of clearance...still not enough I think.

I checking with Tom at CPP to see if the roller clutch they offer is any shorter but it doesn't look like it from the pic.

Did you run into this problem?

[Firefytr29wfd]

Originally Posted by kimmer71

I'm working on a similar build with the same clutch. I have a clearance issue where the clutch will hitting the shackle mount when the suspension compresses or articulates. I can't move the engine because of belt alignment issues. This Buggie already has a 6" lift and I don't really want to go any taller. The engine cradle has been dropped 2" in the front already. If I drop it another inch...I get roughly another inch of clearance...still not enough I think.

I checking with Tom at CPP to see if the roller clutch they offer is any shorter but it doesn't look like it from the pic.

Did you run into this problem?

Just checked your post and saw the photo.

Looks like your engine is mounted farther back than mine, my clutch bolt is in front of the shackle. Right now my cart is at stock height, getting a 6" lift in a few weeks. I will be cutting/notching the shackle mount and frame to add some clearance for my clutch.

Here is what my clearance looks like right now at stock height.

[Firefytr29wfd]

Got my cart running/moving for the first time yesterday, spent about two hours running around the farm working the bugs/kinks out of the setup. Love the key start/running full time over a pedal start! Can't wait to get my 6" Jakes A-Arm lift kit and 22" tires in the next few weeks!