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Big Block Talk! Everything about swapping a big block engine into your cart!



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Old 03-22-2009, 08:09 PM   #1
mikeshotrodshop
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Default New BIG BLOCK kid in town! (pics)

New project - 94' EZ-GO GXI804. I purchased it with a bad Robin 295cc. I also just picked up a slightly used (started a couple of times) 16 horse Briggs Vanguard. The engine has been sitting around and the shaft got a little bit rusty - no big deal. I yanked the Robin out by it's neck today and started the transformation. I cut the front engine mount bracket and will replace it with some angle iron and plate steel. I'm also ordering a 5" lift kit for it tomorrow. Once it's lifted I can drop the Vanny in and line it up.

I'll post more info and pictures as the project continues.
Oh yea, I'm going to go with the Caterpillar theme for this one :0)






Here is the John Deere cart I did last year. Still have to paint the rims yellow and finish the trim on the side.

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Old 03-22-2009, 08:13 PM   #2
TheNewGuy
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Default Re: New BIG BLOCK kid in town! (pics)

Cool project!! keep the pics coming The Deere cart looks good!!

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Old 03-22-2009, 08:18 PM   #3
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Default Re: New BIG BLOCK kid in town! (pics)

good project. i like the deere carts also nice job.
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Old 03-22-2009, 09:02 PM   #4
mikeshotrodshop
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Default Re: New BIG BLOCK kid in town! (pics)

Thanks guys!

I forgot to tell ya's that the Vanny has an electric and pull start. There is no way I'd pull that thing every time I wanted to push the loud pedal.
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Old 03-22-2009, 09:07 PM   #5
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Default Re: New BIG BLOCK kid in town! (pics)

Quote:
Originally Posted by mikeshotrodshop View Post
Thanks guys!

I forgot to tell ya's that the Vanny has an electric and pull start. There is no way I'd pull that thing every time I wanted to push the loud pedal.
that pull start saved me from a 14 mile walk back to camp one time, my battery shorted out on the frame and melted the post off.
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Old 03-23-2009, 05:50 AM   #6
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Default Re: New BIG BLOCK kid in town! (pics)

Quote:
that pull start saved me from a 14 mile walk back to camp one time, my battery shorted out on the frame and melted the post off.
I actually think it's a benefit of having both worlds :0)
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Old 03-23-2009, 12:36 PM   #7
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Default Re: New BIG BLOCK kid in town! (pics)

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Originally Posted by mikeshotrodshop View Post
I actually think it's a benefit of having both worlds :0)
your right best to have both especially when far from the beaten path. beats having to leave your cart and walk.
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Old 03-27-2009, 10:25 PM   #8
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Default Re: New BIG BLOCK kid in town! (pics)

Tonight I spent some time in the garage working on the Vanny. First I started by drooling over the parts from CPP

Then I went to town...

I split the case and removed the cam shaft. Before I installed the 280 Cam, I cleaned the cam and made sure there weren’t any imperfections (I've been building race engine for years and this is just common practice for me). Then I coated the lobes with cam lube from Crower; had some left over from a project.




Before I installed the cam, I removed the tappets and coated the stems with cam lube to hold them in place. I installed the cam and lined up the timing marks.


After the cam was installed, I re-installed the cover (with a new gasket) and installed the 780 clutch. However, before the clutch was installed I pasted the shaft with never seize, this way it will be much easier if it has to be removed in the future.


Picture of shim I stole from a rotor kit for my Harley. It worked perfectly and it’s hardened…


Next, I installed the rev-kit. I removed the rocker covers and the rockers. This engine happen to come with 2-steel push rods, so I didn’t need to use the ones in the kit. The springs compressed easily with my spring compressor tool.


For those of you that have never done this before, you may want to throw some rope down the spark plug hole (see pic) and bring the piston up on TDC (top dead center) or as close as you can get. This way if the valve drops it won’t get lost in the cylinder. If that happens you will use every four letter word you can think of.
I then installed the shims (3-per valve spring) along with the new hardened spring retainer.



Before and after picture of rev-kit installed.


From my many years of engine building I know to check for spring bind. This makes me nervous!!! I do have about .022 of clearance, hopefully this will be enogh for the little guy. We'll see.......


Now that I finished with the valve train, it was time to install the advance keyway. I removed the blower housing and pulled off the fan.


Installed the new key way.


Voila! Job complete…. I also never seized the tapered shaft in order to get the correct torque without galling the shaft.
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Old 03-28-2009, 07:31 AM   #9
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Default Re: New BIG BLOCK kid in town! (pics)

Heading back out to the garage to finish up the engine mount. I'll post more pic's of the progress tonight.

Here is the front mount.
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Old 03-28-2009, 08:27 AM   #10
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Default Re: New BIG BLOCK kid in town! (pics)

Very nice. You'll really enjoy the new power. CPP's rev kit is a must have Vanguard upgrade. Keep the pics comin
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