1986 Marathon, 1991 C/C rear diff, 480 Phazer sled motor

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Starting a new project. Taking my 86' Marathon, swapping out the rear diff to a 91' CC rear end, and installing a 84' Yamaha Phazer 485 sled motor with electric start. Also building a new custom 6" lifted front axle that is 4" wider for stability. Does anyone know of any heavy duty driven clutch that will fit the Club Car rear end? Also does anyone know of any drive belts longer than 56".

First pic is the cart when I got it 10 years ago.
Second pic is the same cart with 4" lift and 22" tires
Third pic is the 6" lift axle +4" in width that i just made, but not finished, still need to weld in the gussets.

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Finally got sled motor pulled and wiring harness removed.
Started to lay out new swing arm assembly. Using the stock EZGO swing arm with the Club Car rearend. I unbolted the EZGO rear diff from the swing arm and plan to mount the club car diff in the same manner using 2-1/2" box tubing to slide over the swing arm tube and mount to the new rear diff. Instead of using new spring perchs to mount the rear diff to the box tube, I am just going to cut out 2-1/4" arcs in the box tube. Will post pics tomorrow of layout. Does anyone know off hand of any coil over shocks that are roughly 6" longer than the stock rear shocks on a Marathon?

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I finally answered one of my own questions, came across the CPP10 clutch. Has anyone used this mated up with a sled engine? So far this is the only clutch I have came across that will bolt up to a stock club car DS differential and allow me to run the wider belt. Does anyone have any other ideas?

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I just ordered a set of shocks to test out on the rear. My stock rear shocks were 11" on centers and it looks like the KFX400 and Z400 front shocks are 16.5" on centers. Going to give them a try with my 6" rear lift just to try out. I still will be using the original springs with a custom spacer.

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Got off work tonight and thought I would quickly mock up the swing arm and the rear end. Shocks should be here Monday or Tuesday then I can weld in the shock mounts and the spring spacers. Cable ties are just to hold the rear end from rotating while I played with it. Also managed to get my gussets cut for my front axle. Slow but steady progress.

[Pitbull Joe]

Gonna be a sweet build.

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Originally Posted by Pitbull Joe

Gonna be a sweet build.

Thank you. I got a little spare time today to do some more welding on the swing arm. Welded in the extensions on the front of the swing arm and also welded in the spring spacers on the rear. Installed cross member to stiffen it up until motor mount in installed. Shot a little paint on it to keep it from getting surface rust while I play around with it. Plan to set the rear end on it tonight and maybe put it back under the cart to see how it fits.

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Temp hung the swing arm tonight after work and set the rear end under the swing arm. Everything fits so far. Still waiting on shocks next week. However I noticed a mistake I have made. When I built the rear lift I did not build it off of the center line of the axle, I build it off of the top of my swing arm. The top of the old rear end axle tubes was 1/4" below the swing arm. When I made my axle mounts I used 2-1/2" box tube and the arcs I cut in them only went 1-1/4" into the tube leaving 1-1/4" of material above the axle tube. Which means the rear of my cart not sets 1"~1-1/4" higher than the front. Not sure if I will try and fix it or leave it this way. Tomorrow I may and try to weld the axle to the swing arm, and start stripping the engine compartment and the roll bar and from bumper.

[Pitbull Joe]

Looks good man. Is there a way to lift the front to match the height of the rear?

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Originally Posted by Pitbull Joe

Looks good man. Is there a way to lift the front to match the height of the rear?

It would just have been easier to fix the rear end. However I had the chance today to recut the rear end mounting block, but I chose to leave it alone. The picture I took last night really exaggerated the rake. When you stand back and look at it, it does not look bad at all. Several people who saw it today said to leav it alone. Plus once there is a little weight on it it will almost be level.
Anyhow today I noticed I made a big mistake yeterday welding in the spring mounts. I somehow managed to offset them 1-1/4" off center. I layed it out that way for some reason so today I cut them off and move them to the correct location. I really love doing things twice. Also I went ahead and welded the rear end to the swing arm and welded the gussets in on the front axle.