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



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Old 09-22-2014, 09:07 AM   #1
DanEzgo
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Default Mercedes Stretch Ezgo Big Block Build

So a little background information first; I live in an area where golf carts are used for traveling to just about wherever you want to go. Having said that, I have wanted to have something unique. I have an older 4 seat pds electric that works well, but pretty boring. The more fun cart is a 2008ish gas st with a dump bed. Like that cart (its lifted, brush guard, lights, etc.) So onto the unique build. I had an opportunity to pick up a 1929 replica mercedes gazelle kit car. It is roughly 5 feet wide by 12 feet and change long. So with the exception of being a bit wider, it is about the size of a six seater. I may section out the fenders and narrow it up a bit if it looks too wide. Thats a whole other topic to get to later. The frame is a 1994 ezgo gas. I bought it as non running for pretty much nothing. I took out the engine, rear axle, removed body, (basically its just a frame with a few components on the front I left on for the moment).

I am sure I will get a ton of opinions on this next part, but I needed to stretch the frame about 29" to get the correct length. I read the posts here and digested all the information before going about it. No, I am not worried about alignment. And before someone says I shouldn't use angle iron, I'm not, its just there for a test fit. I'll be using box tube, inside and outside plus some cross bracing here and there. I talked to a structural engineer and got her thoughts on it. I am planning on using a clone big block. Budget is not a huge issue, but for my planned use, I think its wiser to save the $$ and go with a clone. I have a harbor freight store within minutes from the house, so buying a predator 420 is looking like whats going to go in it. If I had to return it under warranty, shipping is not a concern, so...... I'm willing to try it.

I guess I should elaborate on the mercedes body. It is all fiberglass with the exception of the fender supports being steel. It weighs about 200 pounds or so all in. It was designed for a 1971 vw superbeetle. It had been installed on a car decades ago, but had been removed and was sitting in a guys backyard. One of those he thought he would make a project and it never happened.

Plans besides making the body fit on a stretched frame and dropping in a big block (dropping it in makes it sound easy right?), include re chroming some of the misc parts that are original to the body. There is a mercedes hood ornament as well as a huge chrome grill for the front. I don't plan on lifting or going with any crazy suspension, although I may consider a independent front suspension, just because of clearance issues I may run into.

I plan on making the build happen rather quickly. Don't want to rush anything, but also cant wait to ride around in it and gets tons of looks.

I am going to try to post a picture of two. I'm open to anyone's creative ideas or thoughts. Just remember this is my first big build, not an expert by any means.
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Old 09-24-2014, 09:15 AM   #2
DanEzgo
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Default Re: Mercedes Stretch Ezgo Big Block Build

I put a stock wheel under the fender to get a look at how low / how big of a rim and tire I can fit. I think its going to work perfect.
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Old 09-24-2014, 11:04 AM   #3
hookm
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Default Re: Mercedes Stretch Ezgo Big Block Build

That's going to be kool Dan,keep up the good workhookm
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Old 09-24-2014, 11:51 AM   #4
CajunDavid
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Default Re: Mercedes Stretch Ezgo Big Block Build

Cool, keep us posted!
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Old 09-29-2014, 12:55 PM   #5
DanEzgo
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Default Re: Mercedes Stretch Ezgo Big Block Build

I got the two inner frame rails all welded up with box tube that is sleeved inside of the existing tube at the connections. I still need to drill 2 holes in each and bolt them up for added strength. I am really surprised how strong it is without the outside rails or any inside cross bracing. Has anyone narrowed the top front of their frame. I am going to have to take 6" out of each side to make the hood fit. Wondering what the best way to reinforce that is. Thanks
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Old 09-30-2014, 09:41 AM   #6
DanEzgo
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Default Re: Mercedes Stretch Ezgo Big Block Build

Got a delivery yesterday of some goodies. Heavy duty leaf springs, shocks, bushings, drive belt and some new brake shoes. Rear axle is locked up, hoping it is just the brakes and not the diff. Although, may take that apart and see what shape it is in anyway.
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Old 10-07-2014, 08:42 AM   #7
DanEzgo
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Default Re: Mercedes Stretch Ezgo Big Block Build

More progress. Test fit to check the body and stretch. Mostly there, but will need to get creative on the drivers side front end.

I also tore apart the rear end and sure enough, the brakes were what was locking it up. Cleaned all that out, and then some paint. Sorry it was late and dark out.
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Old 10-08-2014, 06:00 AM   #8
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Default Re: Mercedes Stretch Ezgo Big Block Build

Man that body is huge! You sure it's gonna fit? LOL That will be one big golf cart. I hope you will have some power for that beast....
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Old 10-08-2014, 09:01 AM   #9
DanEzgo
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Default Re: Mercedes Stretch Ezgo Big Block Build

Made a fair bit of progress last night. I went ahead and installed the rear, with the exception that somehow I lost the rear leaf spring hangers. I guess that is what happens when you let your garage get messy. Anyway, I backed the frame back under the body and lowered it for a test fit.

You can see where the rear wheels are without the fenders on the body. Without the fenders, the body is almost perfectly the same size as a standard txt. But, the fenders add 9 inches to each side. I can either leave the fenders at their 9" or section them and take out about 4". Im leaning towards leaving them as they are. I don't mind fiberglass work, but seems like a lot of work. I am thinking of using a custom 7" wheel spacer, and getting wheels with a 1.5" offset (for the rear). The front can do with less width, more on the lines of a total of 6" additional.

Next up is removing the brake assembly and modifying the steering column. I measured the total length last night and with the light bar that goes on the front, it will be just a little over 12'. I looked up a shuttle 6 and that is right under 12' so I think I will be ok with length. Still going back and forth on what to do with the width.
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Old 10-08-2014, 11:25 AM   #10
hookm
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Default Re: Mercedes Stretch Ezgo Big Block Build

Dan,if I was you I'd set the engine in before you tie anything down,I made that mistake on mine & lucked out, barely
It looks like the engine will have to be too forward for the seats,just a thoughthookm
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