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



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Old 12-08-2007, 09:54 AM   #1
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Default Forum Newbie - 18HP Vanguard Install

I just finished buttoning up the cart after installing the 18HP Vanguard. Thanks go out BIG TIME to Tom and Bruce, who helped getting this engine into my 1990 Club Car. There were a few kinks (aka surprises) that had to be ironed out since the kits were originally set for 1992 and up. By the time this was over, the DHL guy and I were on a first name basis……

My original flathead had come unglued inside, and it was just not in the cards to rebuild it. There was considerable cylinder damage due to parts flying around inside.

The engine removal was a piece of cake compared to getting the secondary off the tranny. Everything was tried to get that baby off, heat, penetrating oil, wedges, pullers, hammers, cussing, all to no avail. In the end, I started with the big metal eating tool, a sawsall, and cut the secondary into pieces all the way down leaving just the center sleeve. Once down to the sleeve, the hand grinder was used to ‘carve’ two grooves in the sleeve, one right over the keyway, and another on the opposite side, so the sleeve could be split. The pictures show the final ‘debris field’ along with 2 shots of the split sleeve.

It’s easy to see why the sleeve would not come off; there was a bunch of rust ‘gluing’ it to the shaft.

The tranny shaft was wire brushed and ‘polished’ up till it looked new. It was then liberally coated with T9 to inhibit rust. The sleeve of the secondary was also sprayed with T9, and then slid onto the tranny shaft and secured.

When drilling the plate for the new engine, I drilled 7/16” holes rather than 3/8” (just in case I needed a bit of ‘slop’). In dropping the engine in, I was unable to slide the base forward enough to line up the mounting holes. Seems that on my mounting plate, what looked like washers (~2” diameter) were welded to the plate, and the weld ‘pool’ and washer was preventing forward movement of the engine base. So, out comes the engine, and the grinder; the rear sections of the weld ‘pool’ and washer are ground off to be flat with the plate.

So, back in with the engine…. This time the sawsall cut the center section out of the forward body support frame to make the ‘drop-in’ easier. A section of hefty angle aluminum was cut and fitted as a replacement, countersunk bolts securing each end to the remaining supports.

Install of fuel lines, control cables and wiring were completed; a small problem cropped up at the governor end of the accelerator cable; there were no ‘bosses’ on the forward end of the tranny housing to bolt the cable end bracket to. Evidently some years (?) had bosses, and some did not…… Tom came to the rescue and fabricated a bracket, which worked like a champ.

While installing the wiring in the electrical box, I decided to wire the neutral microswich on the shift lever into the blue wire connected to the starter solenoid to prevent the engine from being started unless the shift lever was in neutral. I was concerned that Annie might have her foot on the accelerator, be in gear, and start the cart…. That would not be a Kodak moment!

The battery was connected, oil put in, everything checked and rechecked.. Turned on the key, hit start – nothing……. Recheck everything – forgot to reinstall ground strap from the frame to the engine block – dumb a$$... Hit start, a bit of spinning, then VARROOOM……

Cautiously backed out of the garage, ran up and down the driveway, the finally to the street. After getting used to the new accelerator travel and feel, ran it around the block a few times. All I can say is WOW, what a positive change…… Took the GPS out for a spin, the cart clocked at 26-27 when opened up. Have not tried adjusting the heavier spring/washer combo yet, I’ll do that after I get a few hours on the engine.

Many thanks to Tom and the crew for a GREAT upgrade, and superb support. I’m sure when that phone rang he thought, “oh that PITA again”…..

Any suggestions for ‘tuning’ up will be greatly appreciated…..

Henri
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Old 12-08-2007, 10:11 AM   #2
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Default Re: Forum Newbie - 18HP Vanguard Install

Welcome to the forum!! Great post!!

Glad it all worked out. The guys at CPP are the Big Block Kings!!!

Lets see some pics of your cart.

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Old 12-08-2007, 10:17 AM   #3
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Default Re: Forum Newbie - 18HP Vanguard Install

Awesome. Big blocks Rule Nice job working your way through the install. Tom was always there to help when we did the upgrade. Send us some pics of your cart. We love pics. And welcome to the forum.

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Old 12-08-2007, 02:28 PM   #4
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Default Re: Forum Newbie - 18HP Vanguard Install

Very cool man. As the others said, lets see some pictures of your cart and the engine as well. Im sure its alot more fun to drive! Good job
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Old 12-08-2007, 03:17 PM   #5
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Default Re: Forum Newbie - 18HP Vanguard Install

Welcome to BGW!! Congrats on the big block!!
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Old 12-23-2007, 04:22 PM   #6
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Default Re: Forum Newbie - 18HP Vanguard Install

Well it took me a while, but below are the pictures of the internal damage to the flathead when it came unglued inside....

It's death was interesting, we were just tooling around, and the engine just lost power like it was running out of gas. Turning the engine manually there was little to no compression. Once inside, the piston could easily be moved side to side with your thumb. The valves were functional, everything at that point looked normal.

The picture below is a shot of the head 'skirt' from the inside. The hole circled in red goes completely through. There is also a horizontal crack in that skirt from the hole, running to the left.

The below picture is a shot of the outside, with the hole circled

The rod, shown below, also had some damage

This is where the part came unglued from. I believe it's called the oil slinger. I guess the screws came loose, and the slinger just fell off.

These are the parts that were floating around, just raisin hell with everything

I have no idea where the part that looks like a pin came from, the rest of the debris most likely belonged to the slinger.

I suspect the cylinder damage is from a 'prior event'. There was carbon in the hole, and the edges were not shiny. Whatever happened earlier must have been repaired(???). The slinger coming into the game was the kiss of death.....

Below are a couple of pictures of the cart, it's pretty pedestrian looking right now. I'd like to get a new top, get it painted, and get some seat covers to dress it better. Anyone with suggestions, speak up, I'm wide open for ideas......




Henri
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Old 12-23-2007, 04:36 PM   #7
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Default Re: Forum Newbie - 18HP Vanguard Install

The oil finger is usually mounted to the bottom of the connecting rod. I am not sure how it is on the FZ340 engines, but that's how it is on most other splash-lubed engines.
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Old 12-25-2007, 08:48 PM   #8
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Default Re: Forum Newbie - 18HP Vanguard Install

Quote:
Originally Posted by RoadRunner View Post
Well it took me a while, but below are the pictures of the internal damage to the flathead when it came unglued inside....

It's death was interesting, we were just tooling around, and the engine just lost power like it was running out of gas. Turning the engine manually there was little to no compression. Once inside, the piston could easily be moved side to side with your thumb. The valves were functional, everything at that point looked normal.

The picture below is a shot of the head 'skirt' from the inside. The hole circled in red goes completely through. There is also a horizontal crack in that skirt from the hole, running to the left.

The below picture is a shot of the outside, with the hole circled

The rod, shown below, also had some damage

This is where the part came unglued from. I believe it's called the oil slinger. I guess the screws came loose, and the slinger just fell off.

These are the parts that were floating around, just raisin hell with everything

I have no idea where the part that looks like a pin came from, the rest of the debris most likely belonged to the slinger.

I suspect the cylinder damage is from a 'prior event'. There was carbon in the hole, and the edges were not shiny. Whatever happened earlier must have been repaired(???). The slinger coming into the game was the kiss of death.....

Below are a couple of pictures of the cart, it's pretty pedestrian looking right now. I'd like to get a new top, get it painted, and get some seat covers to dress it better. Anyone with suggestions, speak up, I'm wide open for ideas......




Henri
Is that Christmas lights on the roof or am I just seeing things?
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Old 12-26-2007, 07:09 AM   #9
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Default Re: Forum Newbie - 18HP Vanguard Install

Quote:
Yamaha4life - Is that Christmas lights on the roof or am I just seeing things?
Yup, nothing wrong with your eyesight.... Found them at the hardware store, 3 double A's, an on/off switch - $2.99...... We usually 'gussie' up more at Christmas, this year the engine swap sorta got in the way - next year.....
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