the Bigcush 74 cushman and 85 atc250es slammed together

old_yamaha

So i bought a crappy old beat up electric cushman for 100 bucks last fall. I had an old Honda atc250es Big red 3 wheeler that was thrashed so i figured id combine the two of them. The 3 wheeler runs like new and has electric start, shaft drive and a semi auto 5 speed transmission. So it was perfect for a beater golfcart. This project is not finished but it is working currently.

So i hacked out the bastardized creation that was in it for a rear axle (someone had a gocart engine in it). I then rolled the cut up atc rear end into place and made some really haggard looking mounts. I spent many hours centering and squaring the axle before final welding of the mounts. I then fabricated a shift linkage, and mounted an old spicer 10spd truck shifter i had. Then i wired the machine to a toggle switch and push button for starting and moved the reverse interlock handle to the firewall for driver access.

Once the machine was running and driving i sorted out some rear body panels made from plywood. i then mounted the rear lights and headlight and wired those in. After that i made a front lift kit to level out the maching using some old atv shocks. I then made up an exhaust using an old muffler from an unknown atv. It pretty quiet but im still trying to find a way to make it quieter.

As of now the unit still needs the roll cage finished and installed, the seats need reupholstered, the body is gonna remain beat up because its for trail use, and im still waiting on my wheel spacers and new rear brake shoes. But for now its good enough to put around the neighborhood on. I will update this post as i make progress on the machine. Youtube links will be added below.

https://www.youtube.com/watch?v=xN1qFSb88ic

https://www.youtube.com/watch?v=ot8JQrBLftA

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BGW

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old_yamaha

more pictures

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old_yamaha

and a few more

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Unforgiven

Wow,.... I love it.

One thing I've run in to with my build is engine heat. May think of a vent fan of some sorts.

Awesome project. Them old big reds are just time tested. Can't wear them out.


oh btw,... I've seen some builds where they put a small car muffler behind the primary muff to hush it up a little.

old_yamaha

So I took it to a local mud bog to test it out. Brought along my buddy with his stock g9. Drove it around for 3 days with zero issues. Engine remained cool, never got stuck and definitely had a good time. My favorite thing to hear all weekend was people saying, "how the hell is he shifting gears on a golfcart?" lol I even pulled a bunch of quads out with it hahaha

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Unforgiven

Good to hear. Looks like fun. That's why we do these crazy builds.

I saw the rest of the donor in one of your videos. Thought it was a Fat Cat.
That's what I want to build, a off-road chopper.

old_yamaha

fleet of **** lined up

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