Ezgo 4-caddy 4x4

BryanW

Hello all, new here. Thought I'd share my current project, it's an Ezgo 4-caddy with 4-wheel independent suspension. The donor quad is a Suzuki King quad 300.

The cool thing about it is how the rear differential is made onto the engine, it has high-low-super low gearing, 2wd-4wd-4wd diff lock, and all functions are controlled by cables.

So far it seems like this quad was made for a buggy swap, the engine fits perfectly in the 4-caddy because of the added space under the rear seat. the stock atv exhaust even fits with a turn down.

Believe it or not, the stock ezgo steering even lines up and will work with the ATV tie-rods. Although they have to be shortened by about 3/8" and bushing made to fit the larger ezgo holes.

This will be a longer project as I get time around other work, but as of right now I have it mocked up and everything tacked in place. The quad only needed to be stretched 24" for everything to line up properly.

So far the bad: No aftermarket wheels, rear wheels set in too far and scrub inner stock fenders, going to attempt to convert all 4 to 4x110. rear brakes are cable while front are hydro, trying to work out a conversion or dual function pedal.

My end goal is to have it look as stock as possible from the outside, build a roll cage, do a full dash customization, audio, digital dash with speedo-tach-temp, either bucket seats or a custom built set-up.

In the pictures it looks pretty rough as I was trying to make sure it'll even work before fully committing to it, now have it broken down for welding, bead blast and paint on frame.

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BGW

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BryanW

Here's a few more pictures, will get more as I progress if anyone is interested.

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ironmonkey17

looking good can't wait too see more
by the way welcome to the addiction..

neonacr24l

id like to see some build pics if you can post them...curious to how the frame work was on the 4wd system. what did you do to extend the driveshafts.....this build has my attention

neonacr24l

concentric wheel spacers with what ever bolt pattern you want. Most companies that make them will custom make the bolt pattern for your application for a little extra.

digital dash? Easiest way to have that is a Trailtech vapor which is about 100-150 on ebay for different styles. MPH, TACH, SHIFT LIGHT, WATER TEMP, OIL TEMP, CLOCK. HOUR METER....

Can get a signal indicator bezel for it that includes indicator lights for low and high beam light

http://www.ebay.com/itm/NEW-TRAIL-TE...NWSo4S&vxp=mtr

or I just found this....now im thinking of myself not buying the vapor anymore and getting this...its cheaper and has more features.

http://www.ebay.com/itm/Universal-Mo...FWJInk&vxp=mtr

BryanW

To extend the frame was to extend the lower 2 tube rails by 23-1/2", in the process of cross bracing it because the frame to cart frame tubes go up like \_/, the cross bracing will prevent any inward bending. The front and rear will be welded to the cart once engine build and paint is done. I'll get better pictures once I get back to it, right now the tack welds look HORRIBLE because my welder was messing up but I had to get it done so I can get it off my lift, it's holding up paying jobs.

The 4wd system is just a drive shaft with 1 u-joint, slip shaft and on the front it has a 6-way mounted rubber joint. Will be cutting both ends off and fitting them into a longer tube, may send it out to be done so it's true and not vibrating/wobbling.

I have been looking at the trail-tech, but the king quad has a factory cable driven speedo, when I get to that point I will be looking into fitting a cable to electric sensor to the factory trans setup, if I can find one that'll fit.

On the wheel adapters. I REALLY hope to avoid them as I want to run a 4-3 or 2-5 wheel on rear and 5-2 on front. By looking at the hubs I believe I can machine new lug holes without interfering with the brakes or hub strength. Stock is 4x140 front and 5x160 rear. They DO however sell 15" wheels for that pattern, but I'm hoping to run a 26x12.5x12 rear and 25x9x12 front.


This is the style dash I am think about, but hate to pay $175 just to cut it up and glass in the digital dash. So may try to fab something up, not sure yet, that's a long ways away.
http://www.ebay.com/itm/111888753310...%3AMEBIDX%3AIT

I see many style atv's daily, work on them for a living/hobby. From the moment I laid eyes on the king quad the first thought I had was this build, it's almost as if it was made for the swap..

It's going to be a very long build, hoping to make it into a show piece for business.

Unforgiven

You won't need wheel spacers on a IFS/IRS bike. Just land you some ATV straight axle rims. You just need more off-set. They are a dime a dozen on Craig's list.

Oh and welcome to the Nut House. Sounds like your build is going smooth. I like it,....

Unforgiven

On a lighter note:
Looks like if you flip the rims, by taking the rights and swapping with the lefts your problem is fixed.

BryanW

It's not that simple with the king quad, the rear lug pattern is 5x160 and front is 4x140, no aftermarket ATV wheels available. So adapters are needed or redrill the hubs. The rear can be flipped around and will work, but hoping to work out some better looking wheels.

Unforgiven

I'd still flip them until you figure something out. I would imagine that a good machinist could redrill the hubs.