lifted club cars - lifted ezgo
Home FAQDonate Who's Online
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Gas Yamaha
Gas Yamaha Gas Yamaha Golf Cars; G1 through "The Drive" and U-Max Utility Vehicles



Post New Thread  Reply
 
Thread Tools Display Modes
Old 08-14-2010, 10:55 AM   #1
jigwelder
Not Yet Wild
 
jigwelder's Avatar
Yamaha
 
Join Date: Jun 2010
Location: Melbourne, Florida
Posts: 35
Default Yet Another G9 build!

I had this golf cart given to me a few years ago and let it sit in the back yard for way too long. It is a gas powered g9 that ran Ok but the engine had a rod knock. Since I had an extra 8hp Briggs flat head laying around I decided to do an engine swap. In order to mate the Yamaha clutch to the 1" Briggs shaft I had to pull it apart and bore the center to 1 1/8". This allowed me to press in and weld a piece of thin wall cro-moly tubing with a slot cut along it for the key to engage.








Long story short it ran pretty well. Clocked it at 26 on the GPS with stock 18" golf cart tires. While on a midnight run the right side wheel and hub broke off of the lower control arm. From this moment on a simple re-power project turned into a very extensive project....clone swap, trx450r front suspension and brakes, 3 link rear.....

Hope you enjoy it!
jigwelder is offline   Reply With Quote
Alt Today
BGW

Golf car forum Sponsored Links

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum
   
Old 08-14-2010, 11:03 AM   #2
jigwelder
Not Yet Wild
 
jigwelder's Avatar
Yamaha
 
Join Date: Jun 2010
Location: Melbourne, Florida
Posts: 35
Default Re: Yet Another G9 build!

Picked up a 2005 Honda trx450r front suspension off ebay for a hundred bucks. Note: If I had to do this over again I would just build my own a-arms and spindles. Honda spent many years perfecting their design and without exact measurements taken from a 4wheeler it was very difficult to get everything right. (Caster, camber, bump steer)

The Teardown:


Lots of rust, upper a-arms tacked:

jigwelder is offline   Reply With Quote
Old 08-14-2010, 02:36 PM   #3
pocket aces
Gone Wild
 
pocket aces's Avatar
Yamaha
 
Join Date: Jan 2010
Location: Tampa, Fl
Posts: 490
Default Re: Yet Another G9 build!

WOW! You got some mad skillz! You go man.
pocket aces is offline   Reply With Quote
Old 08-15-2010, 06:18 AM   #4
jigwelder
Not Yet Wild
 
jigwelder's Avatar
Yamaha
 
Join Date: Jun 2010
Location: Melbourne, Florida
Posts: 35
Default Re: Yet Another G9 build!

Thanks. Just a backyard mechanic.

The reason I ended up tearing the whole cart appart is because I found a crack in one of the main frame members. I decided to cut this section our of both sides and sleeve it with some fresh new tubing. All said and done should have built a frame from scratch.









Was going to go with a 6" stretch but decided to stick with stock.





More to come!
jigwelder is offline   Reply With Quote
Old 08-15-2010, 06:46 AM   #5
technoid
Getting Wild
Yamaha
 
Join Date: Aug 2010
Location: PA
Posts: 138
Default Re: Yet Another G9 build!

Quote:
Originally Posted by jigwelder View Post
Thanks. Just a backyard mechanic.

The reason I ended up tearing the whole cart appart is because I found a crack in one of the main frame members. I decided to cut this section our of both sides and sleeve it with some fresh new tubing. All said and done should have built a frame from scratch.









Was going to go with a 6" stretch but decided to stick with stock.





More to come!
Just a small tip from another back yard welder. For a good weld with solid penetration, be sure to remove all rust from the metal. Even on the inside of tubing. Your project looks good. Makes me want to go out to the garage and get the Mig welder running.
technoid is offline   Reply With Quote
Old 08-15-2010, 07:41 AM   #6
jigwelder
Not Yet Wild
 
jigwelder's Avatar
Yamaha
 
Join Date: Jun 2010
Location: Melbourne, Florida
Posts: 35
Default Re: Yet Another G9 build!

Thanks for the tip. I ran a wire wheel on the inside and cleaned off the paint on the outside before welding. The picture was taken to check out debth of insertion.

Frame back together:
jigwelder is offline   Reply With Quote
Old 08-15-2010, 09:36 AM   #7
sabercat
gone yamaha!
 
sabercat's Avatar
Yamaha
 
Join Date: Sep 2008
Location: ontario, canada
Posts: 1,424
Default Re: Yet Another G9 build!

lookin good so far! everybody loves a frame up resto on these old carts
sabercat is offline   Reply With Quote
Old 08-15-2010, 09:52 PM   #8
jigwelder
Not Yet Wild
 
jigwelder's Avatar
Yamaha
 
Join Date: Jun 2010
Location: Melbourne, Florida
Posts: 35
Default Re: Yet Another G9 build!

Lower a-arm tubing bent. Made a couple of aluminum plates that bolt on at the upper a-arm mounts, saddle the lower a-arm tubing and locate the lower a-arms. Took about 4 tries to get it right.




jigwelder is offline   Reply With Quote
Old 08-17-2010, 09:07 AM   #9
EZ-GOnewild
Gone Wild
E-Z-GO
 
Join Date: Apr 2008
Location: Wichita, KS
Posts: 1,530
Default Re: Yet Another G9 build!

Nice work, looks great. I really like your bench, good idea for a flat surface.
EZ-GOnewild is offline   Reply With Quote
Old 08-17-2010, 09:35 AM   #10
TheNewGuy
Admin/Moderator
 
TheNewGuy's Avatar
Yamaha
 
Join Date: Dec 2006
Location: Ohio
Posts: 18,010
Default Re: Yet Another G9 build!

Yep, nice job! Keep the pics coming.

TheNewGuy is offline   Reply With Quote
Reply

Tags
3 link, atv front, briggs, clone, g9 yamaha
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Gas Yamaha


Thread Tools
Display Modes


Similar Threads
Thread Forum
GEM car build Extreme DC!
my G2 build Gas Yamaha
G1 build Members Rides
Another G21 build Lifted Golf Carts
(3 48v build Electric Club Car


All times are GMT -5. The time now is 05:55 AM.


Club Car Electric | EZGO Electric | Lifted Golf Carts | Gas EZGO | Used Golf Carts and Parts

Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2024, vBulletin Solutions, Inc.
This Website and forum is the property of Buggiesgonewild.com. No material may be taken or duplicated in part or full without prior written consent of the owners of buggiesgonewild.com. © 2006-2017 Buggiesgonewild.com. All rights reserved.