Project Sideswipe. EFI Sportsman+G1=4X4 cart

michale

Howdy, I started a new build over the weekend and welcome all input ,positive or negative. I have a 2006 Sportsman X2 that was recently rolled at 40 MPH and a G1 that is dead so I figured why not add more power to the cart. First I was just going to take the motor and install it in the cart. I figured the EFI 500 would push it to about 50 mph without a clutch kit. Then I read on here that the old 2 stroke ran backwards and that's how we get reverse so I figured I would do a simple rear-end swap and use the Polaris independent suspension. Then I got to thinking why not 4X4, how hard could it be?.
Actually I don't think its going to be that tough. I have just about everything worked out in my head accept the steering. Does anyone know if the stock G1 steering box is strong enough for this application? I plan on using the sportsman complete drivetrain, frame, wire harness, fuel tank and so on. I will need to cut the Sportsman frame and lengthen it 7" as well as lengthen the front driveline. Here are a couple pictures of what I started with.

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michale

I haven't figured out how to post pictures then type then more pics then more type and so all on the same post on so I just replied. Anyways, I striped down the cart and Sportsman to the frames, measured, thought some and measured some more. This is what I came up with. I removed the old engine and swing arm complete. More room for the 500 engine, trans, rear end and frame . The X2 frame and running gear are longer then the regular sportsman so either the engine will stick out the front of the rear box or the back of the quad will stick out the back of the cart box. I opted for the latter. I will be installing rear facing seats back there so it will all hide I think. Next I cut the quad frame in half in front of the motor (no turning back now)and dry fit the quad to the cart. The platform will be 24" off the ground to the bottom of it. What do you think,Too tall??

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slonomo

Wow cool project. Got some fabwork ahead of you don't you? LOL

Yeah that's pretty high up there, but with that suspension it will ride super nice. My G1 is 20" to the rockers I think? It does just fine and I have the golf cart rear end. The sportsman suspension is very cushy so when you load it with 4 people it will squat about 6". That will take it down to a more manageable height.

Have you seen the Sportsman Ace? It's a single seater RZR type machine. Yours in going to look like one of those. I haven't seen a G1 with an atv driveline yet. You might be the first?

Unforgiven

Yeah, on my honda 350 I had my cut off wheel running and almost touching the frame. Then cut it off and thought "what am i doing" I know it was a $1200 old four wheeler but it ran good. So after a little liquid courage I split the frame. Neighbor "man you crazy"

I had to cut out in front of the seat for my motor to stick out about 6". I'm going to case this out, place my shifter on top and some switchs.

michale

The X2 came with a dump bed on the back and it has adjustable shocks so I don't see it squatting more then a couple inches. After gutting the cart there isn't much left. Its very light.

I figured out how to post pictures and not just thumbnails where friends have to log in to view so here are the pictures I already posted.

michale

Finally had some time to work on it this weekend. I had to cut the bottom cross brace out of the cart frame so I could slide the motor as far forward as possible. I welded another cross brace 4" forward more.

Next I started connecting the cart frame to the quad frame. The main supports for the cart frame will be attached to the quad frame right at the front and rear shocks. I am also attaching the 2 frames together. I am attaching 1 1/4" schedule 40 pipe the entire length of the quad frame to stiffen it up.

michale

A few more pictures. The tires on it now are 25" tall and it looks odd because of how much room above the tires so I will be installing some 30" tall tires. I was also able to use the stock bar on the back of the quad where the dump bed attached to for the cart body hinges.

michale

I need some opinions here please. Here is a picture of the quad before I cut it up and a blowup of the area in question. I picked up a 14" rack and pinion to install. See the angle of the tie rods? Do you think it would be wise to try and keep the same geometry of the stock tie rods or install the new rack and pinion in more of a straight line with the ball joints? I am trying to keep bump steer down to a minimum. Thank you ahead of time for all your help, M.

tjequip

Keep up the good work

Unforgiven

if your not widing the frame or extending the a-arms, keep it the same geo.

it needs to be parallel to the arms at ride height. But I have a honda that came from the factory and they are not parallel. I'll take a picture tonight