How about a golf cart build?

[92 Green YJ]

Cruising right along on this today. New steering rack installed. I decided to just go ahead and replace all three tie rod ends as well. They are pretty roached. Ordered them today and they are due Monday.

Got the front end completely assembled. New shocks, 2" wheel spacers, new tires and wheels all done. Will wait to set caster/camber/ toe once its on its own weight on all fours.

Then I decided to start tackling the "interior a bit. But i hit a snag. My standard automotive steering wheel puller won't work to remove this steering wheel. so i took some of the plates from the old suspension, cut a slot in the top plate, welded a washer and nut to the bottom plate, bolted them together with some hardware i had floating around, and voila. custom golf cart steering wheel puller.

With the old wheel off I went ahead and installed the new dash, new ignition switch, and the old oil light

Followed by the steering wheel adapter and new steering wheel

Now moving to the rear lift kit and I knew this shit was going too easily. every single leaf spring bolt is frozen to the bushing sleeve. So i am having to cut them all. Luckily it appears I have the right size hardware on hand already to replace them. There is quite a difference between the original leaf springs on this thing and the new heavy duty progressive rate springs I am putting in.

 

[aczlan]

There is quite a difference between the original leaf springs on this thing and the new heavy duty progressive rate springs I am putting in.

Curious to see what you think of how it rides with those springs.
Mother in law has similar looking springs in her electric cart and they ride super rough.

Aaron Z

 

[92 Green YJ]

Pushed thru to get few more things done. Installed the new rear springs and the SOA conversion brackets to get the rear lifted.

Went ahead and replaced the rear brake shoes as they were pretty much down to the backing plates. New rear shocks in. rear wheel spacers and back tires and wheels installed.

Right when I was fixing to call it a day UPS showed up with a few more pieces. The new front brush gaurd

And the new rear heavy duty tow hitch set up. Since it was only four bolts I decided to go ahead and put the hitch on before calling it a day.

 

[92 Green YJ]

Curious to see what you think of how it rides with those springs.
Mother in law has similar looking springs in her electric cart and they ride super rough.

Aaron Z

We shall see. I know the lift mentioned in their literature that 23" tires may rub if the factory rear springs were retained. So they suggested switching to a heavy duty leaf spring to offset that.

 

[Chkn]

Updates?

 

[92 Green YJ]

Updates?

Yeah I know. Been busy with the new dogs and knocking out my online Animal Control Officer certification course. Life’s been getting in the way. Hoping to get some time on it tomorrow. Paint and supplies came in as did the new tie rod ends, diamond plate rockers, and the soft top for it.

 

[92 Green YJ]

Finally got the chance to get back to work on this thing today. I started off with installing all the new tie rod ends and doing an alignment.

Then I installed the new rocker panels followed by the side step/nerf bars

Then I went ahead and fabricated the new exhaust and got it installed.

Then I jumped to the body and doing the cut outs for the lights

 

[92 Green YJ]

Jigsaw made short work of the body.

After I did the light cut outs I removed the rear flares and sanded the rough spots on the body down. I was actually going to paint it today, but I discovered I am out of paint mixing cups so that’s gonna have to wait until next week.

 

[92 Green YJ]

Today was paint day! Overall I laid down 5 coats of Summit Racing single stage acrylic urethane paint in Plum metallic purple.

This was two coats in

And after 5 coats

 

[Sterlingfire]

Pretty cool.
How much will you have into it all in, if you don't mind answering?

 

[92 Green YJ]

Pretty cool.
How much will you have into it all in, if you don't mind answering?

All in I think I’ll land around $3,500 including the cost of the cart. Not too bad at all in my opinion. Especially to keep the wife happy.

 

[92 Green YJ]

Back at it today. Decided to start off with putting the front clip back on.

Once I got it on I went ahead and installed the new LED headlights. Drilled some holes and installed some 10-24 Nutserts and used some SS button heads I had laying around to bolt them on.

After the headlights I got the brush guard installed. Had to drill some holes as none of them actually lined up

Then I went to install the new drive belt. That's where I hit a snag. Turns out the current clutch is wide open and stuck that way. No amount of prying, hitting, lubrication, etc will get this thing to close down. Which also means I can't get the drive belt on.

Now, apparently this is the old style clutch and there is a new style from the later model carts that is superior. So after some guidance I went ahead and ordered the new style drive clutch and a new style high torque axle clutch set up to replace both of the existing ones. So that means I can't put the rear body back on yet. Its much easier to get to the engine and such with it off so I would like to do all the work under here before i put it back on. So most i could do before calling it a day was to install the front top support bars after a few coats of black paint.

 

[j20brett]

Pretty sweet build. But, does it run yet?

 

[92 Green YJ]

Pretty sweet build. But, does it run yet?

It does! I fired it up yesterday and it fired right up and ran great.

 

[92 Green YJ]

Got some more work done on this today. New clutch came in so I started with attempting to remove that. Clutch removal tool they sent me was the wrong thread size. Scrounged around and found a bolt the right size. Still couldn’t get the fucking thing to budge. Tried to yank it off with a come a long. That didn’t work either.

So out came the grinder and off came the old clutch in lots of pieces.

Then I installed the new clutch along with a new starter and drive belt.

That done I put the main body back on and bolted it down. Started installing the rear flares.

Then brown Santa showed up with the new floor mat and two out of three new pedal pads. So I dropped those in

and finished the day with the tail lights and the 3D printed shifter I made.

 

[Dethmachinefab]

When removing taper shaft stuff like that you need to load it with a puller and give it a good smack to unseat it.

 

[92 Green YJ]

Progress has been slow on this lately. Had another project crop up that’s been taking a lot of my time. But I did spend a bit of time on this today while I was out in the garage. Finished installing the rear seat/cargo deck.

only thing I really need to still figure out is why it does when I put it into gear. It runs just fine in neutral but the moment I shift to forward or reverse it just stalls out.