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Unread 06-14-2015, 11:35 PM   #1
Not Yet Wild
Club Car
 
Join Date: Apr 2015
Location: New Jersey
Posts: 30
Default Converting electric Club Car to 420cc clone engine

Hello all. My name is Steve and I am new to this forum as well as the golf cart scene. I never really considered needing a golf cart until I got a free Club Car from my friends father. Sad story, he was recently diagnosed with cancer and had to close the doors to his EZ Go shop that he owned. Long story short, after helping clean out their warehouse, I found myself the owner of a electric Club Car with a Carryall 2 4'x4' dump bed on the back. The only problem is... there is no batteries or controller(s). So I decided to get this cart going with a Predator engine from Harbor Freight.

Pics to follow...
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Unread 06-14-2015, 11:53 PM   #2
Not Yet Wild
Club Car
 
Join Date: Apr 2015
Location: New Jersey
Posts: 30
Default Re: Converting electric Club Car to 420cc clone engine

Here is the cart when I picked it up a couple of months ago.
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File Type: jpg IMG_1591.jpg (216.1 KB, 0 views)
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Unread 06-15-2015, 12:11 AM   #3
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Default Re: Converting electric Club Car to 420cc clone engine

Some more pics for you. The first couple of pics are of the cart getting stripped down the rest of the way. The third one was me getting an idea of where the engine would be located and how tall it is. It is too tall with the stock exhaust, intake and gas tank which I kind of figured.
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File Type: jpg IMG_1601.jpg (207.2 KB, 0 views)
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Unread 06-15-2015, 12:34 AM   #4
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Default Re: Converting electric Club Car to 420cc clone engine

I got the idea to use the electric motor shaft for the final chain drive thanks to a member on here. I gutted the electric motor which was WAAAAAAAYYYYYY more labor intensive than I thought it would be. I then bought a sprocket for the shaft. Since the shaft was not supposed to have a sprocket on it, it did not have a keyway for the sprocket so I had to cut one with the angle grinder. It came out better than I expected.
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File Type: jpg IMG_1973.jpg (108.6 KB, 0 views)
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Unread 06-15-2015, 12:38 AM   #5
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Default Re: Converting electric Club Car to 420cc clone engine

I wanted a reverse gear though so I had some more research to do. I ended up buying a Comet forward, neutral, reverse gearbox. Then I bought a series 40 clutch for it and the longest belt I could find. The pic is not my actual gearbox.. it was just youtube video I was watching that for some reason saved as a pic on my phone.
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Unread 06-15-2015, 12:49 AM   #6
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Default Re: Converting electric Club Car to 420cc clone engine

I started working on a motor mount. The fact that the frame is aluminum made me a little nervous about strength, so I took some precautions to reinforce it where the motor mount plate was going to be. I had some angle iron that was 3" on each side and fabbed up a motor mount from that. Later I modified it a few times so it looks a little different.
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File Type: jpg IMG_1983.jpg (99.8 KB, 0 views)
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Unread 06-15-2015, 01:03 AM   #7
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Default Re: Converting electric Club Car to 420cc clone engine

After the motor was bolted in, it was time to start mounting the trans and getting everything lined up. Here are a few pics of the Comet trans being sorted out. You will see some wood holding things up in some of the pics. Also the trans mount and bearing block mount that I came up with. You may also notice the gas tank which my friend who I got the cart from gave me as well as a new fuel pump.
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File Type: jpg IMG_2033.jpg (167.7 KB, 0 views)
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Unread 06-15-2015, 01:11 AM   #8
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Default Re: Converting electric Club Car to 420cc clone engine

Since the muffler wasn't going to work in its original location I had to look into my options. I decided to attempt to make my own exhaust pipe to move the stock muffler out of the way. Did I mention that I was trying to do this on the cheap? I saved money by making parts anywhere I could. First I made 2 flanges using the exhaust gasket as a template. Then I searched high and low for some tubing and all I could come up with was a old jack handle that I was using as a cheater bar. It will have to do.

Some of these pics are upside down but you get the idea. I am tired of fixing them before uploading them.
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File Type: jpg IMG_2018.jpg (128.3 KB, 0 views)
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Unread 06-15-2015, 01:19 AM   #9
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Default Re: Converting electric Club Car to 420cc clone engine

More exhaust pics. The muffler is pointing down to exit under the cart. I am going to add a bracket on the frame toward the muffler to hold it for support.

I think this all the updates for tonight... Its late and I am going to bed.
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File Type: jpg IMG_2048.jpg (132.6 KB, 0 views)
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Unread 06-15-2015, 01:21 AM   #10
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Default Re: Converting electric Club Car to 420cc clone engine

More muffler pics.
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File Type: jpg IMG_2047.jpg (131.3 KB, 0 views)
File Type: jpg IMG_2046.jpg (181.3 KB, 0 views)
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