4x4 Marathon / Nighthawk Project and Introduction

Spye

Hello all, I have been lurking for quite a while here and now its time to introduce and tell about my project. I have been wanting to build a 4x4 golf cart for some time and never really wanted to go the ATV route so I have come up with something different. I have a mid-late 80's EZGO Marathon (electric) that I am going to hang Dana 44 high pinion front and rear axles from a Ditch Witch under, and power it all with a Honda 750 Nighthawk engine. I have gathered a almost all of the necessary parts and this will be a slow build (have a newborn son that eats up a lot of time) but should be an exciting one.

Heres a rundown of the parts gathered with some pics below:
1) Mid 80's marathon (running)
2) 1991 750 Nighthawk (running and driving)
3) 27x12x12 GBC Dirt Tamer Tires
4) Dana 44 high pinion axles (front and rear, 43" wide at wheel mounting flange, loaded with 5.88 gears)
5) 12"x11" wide wheels with weld on beadlock kit
6) Springs and suspension components to complete the suspension

Should make an interesting combination when all is said and done. Working on the frame design now. I dont think it will be a good idea to attach those heavy axles and tires/wheels to the standard marathon frame. Thinking of something like a frame on frame type situation and then "Z" ing the front and rear frame horns to lower it back down to a manageable height. Any suggestions on that front?? I am also planning on making an engine cradle that will allow me to attach a jackshaft type setup underneath to split the power to the diff's something like the sand drag guys use for transferring the power to the front and rear instead of a standard transfercase. Also any idea on that front are appreciated.

Spye

Attached Images

	Golf Cart Project.jpg (48.5 KB, 38 views)
	Ditch Witch Axle.jpg (74.2 KB, 62 views)

BGW

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smallblock450sl

Extremly cool project Would have like to see a later model car, but... 43" length diff's with 5.88 gears should be a great ground pounder! Have you considered mounting the engine side ways with drive shafts? Welcome to the madness we call BGW

Spye

Thanks smallblock! Iam actually planning on mounting the engine sideways And then run the chain straight down to another sprocket that is in between two beaings and then on the ends of the shaft there will be yokes that allow me to attach the driveshafts front and rear.

I also would have liked to have had a newer cart but the money doesn't permit it. I got this one from a neighbor for an old sheetmetal brake that was given to me, so cheap it is! I may look into fitting a newer front body to this once i get it built, we'll see.

Spye

smallblock450sl

Why can't I ever find a deal on a sheet metal brake, or a good working lathe Butt hen I don't have a shop to store them in Show us some pix's before you go to far, there are very talented members here and maybe a great idea will pop up to make the build better/safer/stronger.

csason

That drag link looks like somebody hooked to it to pull out a stuck ditch witch.. Those are some monster diffs for a cart.. wow...

I guess Vermeer is a good source of transaxles.. those cable plows are pretty unstoppable.. lol

Will be cool watching it come together..

Spye

Csason: Yeah the tie rod is bent like that to avoid hitting the diff in the middle and there is also a blade in front of the diff on the ditch witch that the tie rod has to bent around. They are heavy diffs and the original intent was a Toro Multipro sprayer that I have with a flatbed, but that thing is slow and only good for crawling around. I wanted something that can be used and have a little fun if I want to abuse it on the trails or something. Lets put it this way, with all of the parts i have I only have about $1100 tied up in this, now my time will be the majority of this project.

Spye

rifter

Sounds like a great build, the frame on frame should work good, I've seen a golf cart body/frame sitting on a Samuri frame/running gear that is a real good working cart.

rifter

Why not fill out your profile so we can know more about "Spye", where are you located?

Spye

Rifter: Profile done, and as for the frame on frame idea, I have to be careful because number 1, i dont want it to be too tall, and number 2, I dont want it to look like a pile of number 2! I am mainly concerned with the unsprung weight of these axles and tires and wheels causing the frame and body to flex real bad.

I want it to appear as a lifted cart but then upon further investigation you realize there is a whole lot more to it.

Spye

csason

I wonder how those diffs are going to handle or perform at really high rpm ?