Hi guys and gals, I kinda new around here but have been reading alot through your forums trying to gather knowledge for my upcoming project. What I found was very helpful and inspired me to document mine as well. It may help someone down the line but may help me more, posting it here as I go and explain my thinking on what I'm doing maybe you guys will see me doing something wrong and set me straight or show me a better way of doing something. Anyways here we go.....I bought this old cart from a guy at work...it had a rod seized to the crank. I brought it home and cleaned it up and started taking it apart and it was in pretty good shape under all the dirt and grease. I have no intention of trying to rebuild the original motor knowing their reputation so I started looking here for ideas on a new motor. As my budget is tight on this project I decided to go with a duomax 16hp i picked up for 299$. When it came in it looked as if it might be damaged, the box looked ruff. It did have a busted air cleaner housing but I plan to hook it to the clubcar air cleaner so no big deal.
Goal - Not looking for a beast, just want to make the cart function as it should playing golf with maybe a little more power. I live in a community that allows us to purchase a tag for our carts and drive them on the secondary roads, and since the course i work at is only a mile away i drive my cart to work alot in the summers.
After getting the cart cleaned I painted the springs, shocks and motor cradle with a fresh coat of black paint. While cleaning and getting my parts together I noticed how bulky the 90 model air cleaner setup was. I got a air cleaner off of a 2003 clubcar. It is much smaller and tucks in beside the battery with a nice newer style element. A problem i ran into was the 03 setup has a air duct the runs under the body and up from to the center to get its air and that duct is requiring some modification to make it work. The frame clearance behind the front wheel where that round bar runs through the frame is tighter so i am cutting the duct around that round bar at that point and going to seal it with some kind of silicon. My cut turned out good and is going to be a snug fit and good seal i believe. Is a pic showing the front piece mounted. I also had to cut a small notch it the brace at the front of the battery box so the duct could fit in under the air cleaner box. I will also have to add a brace under that air cleaner box for it to mount to.
I was at this point when my motor came in and i jumped to it. Engine fever...yeaaaa baby. Ok I took all the stuff off I didnt need, air cleaner, gas tank ect... then placed it in for sizing, wow she is a tight fit. Oh forgot to mention before removing that stuff from the motor I filled it with oil and a little gas and cranked it up. Started on first pull and purred like a kitten. so far so good. Motor set to low just like i read other people saying about their builds. I fabricated 2 motor mounts that raised it 1 1/4". They are just 1 1/4" square tubing 8 3/4" long. I havnt drilled any hole where they will sit yet as I need to get my crank cut and clutch installed to make sure i get good alignment when it all comes together.
As far as clutch I plan to use the stock clubcar clutch, I also plan to mount the clubcar starter and let it do all the work. This model clubcar has the large muffler that hangs under the rear so I plan to fabricate an exhaust pipe to use it. Also plan to hook up the clubcar fuel pump and tank which leads me to my first question......
I see where almost everyone drills and puts in a fitting in the valve cover to hook up the fuel pump. There is a breather hose coming from the valve cover already. Im not sure if this will work but...why cant I run the hose to an intake that I will buy or fabricate on the outside of the carburator for hooking up the air cleaner hose and has a smaller fitting for ....the hose from the valve cover, then I will cut that line and put in a tee that will let me hook my fuel pump vacuum line to. Will this work? or should i plan on drilling and tapping into the valve cover? hope thats not confusing.
Thats as far as I am at this point. I started this project before I thought about posting about it so I didnt take many pictures to this point but will. thanks for all the help I'm sure you guys will give me as this thing goes. Wish me luck. :thumbup:
well it seems i cant post the pictures yet because I havnt been a registered member for 7 days, only 3. As soon as it lets me I will post the pics I have so far.
Goal - Not looking for a beast, just want to make the cart function as it should playing golf with maybe a little more power. I live in a community that allows us to purchase a tag for our carts and drive them on the secondary roads, and since the course i work at is only a mile away i drive my cart to work alot in the summers.
After getting the cart cleaned I painted the springs, shocks and motor cradle with a fresh coat of black paint. While cleaning and getting my parts together I noticed how bulky the 90 model air cleaner setup was. I got a air cleaner off of a 2003 clubcar. It is much smaller and tucks in beside the battery with a nice newer style element. A problem i ran into was the 03 setup has a air duct the runs under the body and up from to the center to get its air and that duct is requiring some modification to make it work. The frame clearance behind the front wheel where that round bar runs through the frame is tighter so i am cutting the duct around that round bar at that point and going to seal it with some kind of silicon. My cut turned out good and is going to be a snug fit and good seal i believe. Is a pic showing the front piece mounted. I also had to cut a small notch it the brace at the front of the battery box so the duct could fit in under the air cleaner box. I will also have to add a brace under that air cleaner box for it to mount to.
I was at this point when my motor came in and i jumped to it. Engine fever...yeaaaa baby. Ok I took all the stuff off I didnt need, air cleaner, gas tank ect... then placed it in for sizing, wow she is a tight fit. Oh forgot to mention before removing that stuff from the motor I filled it with oil and a little gas and cranked it up. Started on first pull and purred like a kitten. so far so good. Motor set to low just like i read other people saying about their builds. I fabricated 2 motor mounts that raised it 1 1/4". They are just 1 1/4" square tubing 8 3/4" long. I havnt drilled any hole where they will sit yet as I need to get my crank cut and clutch installed to make sure i get good alignment when it all comes together.
As far as clutch I plan to use the stock clubcar clutch, I also plan to mount the clubcar starter and let it do all the work. This model clubcar has the large muffler that hangs under the rear so I plan to fabricate an exhaust pipe to use it. Also plan to hook up the clubcar fuel pump and tank which leads me to my first question......
I see where almost everyone drills and puts in a fitting in the valve cover to hook up the fuel pump. There is a breather hose coming from the valve cover already. Im not sure if this will work but...why cant I run the hose to an intake that I will buy or fabricate on the outside of the carburator for hooking up the air cleaner hose and has a smaller fitting for ....the hose from the valve cover, then I will cut that line and put in a tee that will let me hook my fuel pump vacuum line to. Will this work? or should i plan on drilling and tapping into the valve cover? hope thats not confusing.
Thats as far as I am at this point. I started this project before I thought about posting about it so I didnt take many pictures to this point but will. thanks for all the help I'm sure you guys will give me as this thing goes. Wish me luck. :thumbup:
well it seems i cant post the pictures yet because I havnt been a registered member for 7 days, only 3. As soon as it lets me I will post the pics I have so far.