Carry-All II Duromax Install

Boones

I have a 94 Carry-all II, gasser, that is bone stock. Well I did add the upgraded clutch springs. I think one was the 200rpm spring so the cart would idle without kicking in the clutch, the other was the power spring in the rear clutch to keep the rpm's up while in tall grass.


Last year the screw in the butterfly valve in the carb got sucked into the intake. Of course it ended up rattling around in the head for awhile. I pulled the head, removed the screw. (Lots of screw imprints on the head and piston)... I put it all back together and it ran decent for about 6 months. Finally, the engine gave out.. I don't really know what happened I was driving, pulled into the backyard and it shutoff. Oil levels, everything else seemed to be fine. It just died. Of course, over the years, I got the cart used, I found that I was fixing this, than that, you know the routine.

I figured for $300 I can get a new motor, the Duromax 16hp. So I did.. This is my journey. I don't figure I'll ever actually be done with it.... I'm sure there will be lift kits, tires, brakes, etc... I will do my best to keep you guys in the loop on my progress.. But First I need to get you all caught-up on where I'm at now.

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BGW

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Boones

Here are a few more pictures of what I started with..
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I would also like to add this. I've been using the site for awhile now... I've been able to solve a bunch of issue using the enormous amount knowledge posted on this site. I want to give a big thanks to all of you who have posted, and continue to post helping folks like me, who think I know what I'm doing until I get stuck. (lol)

Let the journey begin..

Boones

Here is the new Duromax 16hp getting ready to have the crank cut, drilled and tapped. I cut 1.5 inches off the crank. I could have gone maybe 1 3/4 inches and still had room for the clutch. I drilled the entire depth of the hole, first. I used a smaller bit to make a pilot hole. Then stepped up to the final size bit. I started off with the idea of using the sawzall... But soon changed over to the 4" hand held grinder you see there. Notice I used I grinder wheel and not a cutoff wheel. The grinder wheel did ok.. However, I think a cutoff wheel would have speed up the process.

Yeah that's dried blood on the tape measure... That came courtesy of the keyway that was cut into the shaft... If I could only get my knives that freaking sharp.

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Boones

Few more pictures of the shaft after it was cut.. Sorry if I doubled posted any pictures.

Anyway, you can see from the pictures that I could have taken another 1/4 to 1/2 inch off the shaft.

The adapter you see on the shaft was provided by CPP. Fit perfect.. I might also add that those cut in the adapter are rather sharp.. No I didn't learn the first time I cut my hand of the keyway.

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Boones

While I had the back end out I needed to replace the leaf springs... If you notice some of the earlier pictures, not sure if you can see it or not but all but one of the leaf spring were broken. They all broke where the bushing go... Strange


Anyway I replaced the u bolts and leaf springs. Used some Ospho to stop the rust and then painted it with some brush on rustoleum.

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Boones

Mounting the motor wasn't as difficult as I thought it would. Here is how I did it..

I extended the holes in the original mounting plate to allow the motor to move forward and backward. I had the flip the plate around to make that work so what originally faced forward is now facing backward mounting plate wise. I used a torch to elongate the holes. See pictures of the plate attached to the motor.

Once the motor was attached to the mounting plate I moved on to the other mounts. As you can see in the pictures I used the channel, forgot what its called now, but you can see it in the picture. Under that channel I used the original motor mounts to insulate the motor from the frame. I also used the motor mounts between the mounting plate and the unistrut. Of course I don't have any pictures of that part.
In a nutshell.. Starting with frame... The frame, then motor mounts (2 on the front unistrut, 2 on the back unistrut) the on top of the unistrut are 4 more motor mounts 2 up front and 2 in the back The mounting plate attaches to these mounts.

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70Shaker6pk

Great work, thanks for taking the time to post the pictures, they really help when doing this kind of stuff!

mcdave71

Called Unistrut

clubcar5

Boones, I am in the progress of swaping my FE290 with a GX390 so our journey's are very similar. Would you know how deep you drilled the shaft and what size thread? I am removing my clutch this weekend with a buddy that has the puller. Also, did you have any problems with carb hitting the black box assuming you have to move the Duromax left to line up the clutches? My did so I am fabricating a custom intake manifold to move the carb up and out of the way.

Boones

I'll post sopme pictures to show you how I got the carb setup.. I did need to remove the carb face plate and the black box. After I hooked up the motor. I was able to reinstall the black box.

I will post those pictures today..