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Old 07-09-2013, 11:37 AM   #1
bronsonj
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Default Small blockin' it, 212 HF

Hello all,

I've been here a while, but haven't started a thread because I was getting no time to work on it. Well, I made some decent progress and thought I'd start one. I'll post it all in stages, so here goes.

To start with:
Free - 1985 EZGO electric with all the electrics ripped out and in a real state of disrepair.
$20 HF 212 motor from the guy who gave me the cart. Stock motor, gov removed (so far).
$120 purchased NOS Comet TAV2

The goal is to leave the front stock height, add an inch in rear lift, drop in the clone, paint it black, go topless, put baby moons on and maybe a bigger, baloonier tier in the back too.
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Old 07-09-2013, 11:59 AM   #2
bronsonj
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Default Re: Small blockin' it, 212 HF

Here she is. She looks the same now, except when I got her she had a top frame, bad seat and no motor, but the same ugliness...



So I needed a way to connect power to the rear. On this model, it had an electric motor with the armature sticking out, so I used the motor as a frame to house my sprocket.



Here is the motor assembled, but before I welded the sprocket.
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Old 07-09-2013, 12:08 PM   #3
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Default Re: Small blockin' it, 212 HF

So I tried to figure out how to do an engine cradle. The rear is on leaf springs and a simple pan hinged at the rear and at the frame would've caused binding points. I went through about a dozen design ideas, but the only thing that would work with the rear on leafs was to make a frame for the motor that was fixed ridgidly to the rear diff. So it all would move as one.

so, some 1.25" square tube and a couple exhaust clamps and I was in business. But, that would have a lot of stress on the mount points at the rear diff, so I added a gusset out of 3/8ths flat bar that goes from the top bolt of the diff down to the cradle. Now that it is triangulated, it is quite strong.

Here is the driver's side half of the cradle.


And here is the passenger side and the flat bar.


Here it is with the motor mounted. I created a sub-mount out of more 1.25" square tube and welded that to the cradle.

and
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Old 07-10-2013, 06:31 AM   #4
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Default Re: Small blockin' it, 212 HF

I had it on the jackstands before and it ran like it should, but I had no throttle or kill switch so I didn't want to have it running on the ground yet.

Well, I hooked up the throttle and kill. Had it on the ground and standing beside the cart, I gave the pull cord a yank. It started and took off across the yard without me!

Luckily the throttle cable wasn't too tight, it was maybe 1/4 throttle or less so I was able to catch it and flip the kill.... and found out my new kill switch didn't work... But I was able to hop on and drive it back.

So, good news, it does go under it's own power.

I did get the kill switch fixed, but throttle is still needing attention. I am using a bicycle cable for throttle so I stopped by the BMX shop to get some cable stops and bits. Now I need to fab a bracket for the mount on the motor and how it hooks to the carb.

Family is back in town now, so progress will get slower, but I don't have a lot of functional stuff to do still... Hoping to get the throttle settled tonight and then start to think about exhaust.

Here is where I need some help. I have never built an exhaust before. What kind of pipe should I use for that? A buddy suggested metal conduit, but I don't know if that would hold up. What are your thoughts?
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Old 07-10-2013, 07:45 PM   #5
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Default Re: Small blockin' it, 212 HF

You can get sections of pipe and make your own, or the easy way like I did and call robertson torque tubes and have it made just like you want. He also has kits. He make a lot of exhaust for gokarts and other things. I used a car muffler. The golf cart places like NR racing have pipe parts as do other places, though they don't use much of a muffler on gokarts. Sounds like you are close to having it going!
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Old 07-10-2013, 08:21 PM   #6
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Default Re: Small blockin' it, 212 HF

I gotta admit, using the motor housing and shaft like that was pretty slick.
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Old 07-11-2013, 06:25 AM   #7
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Default Re: Small blockin' it, 212 HF

Thanks Sho and roady.

It was actually quite fun pulling out the torch and welders to work on this thing. I am looking forward to making the exhaust. Thanks for the heads up sho, I really didn't want to use conduit...

Sho, did you find the car muffler gave you a lower tone? I just don't want to sound like a lawnmower.

Lastly, any recommendations on backpressure? I know that some engines prefer a lot, some prefer as little as possible.
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Old 07-11-2013, 09:02 PM   #8
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Default Re: Small blockin' it, 212 HF

These seem to run best with a header or a lawn muffler made for them. I put a 1" header on my 420 to the car muffler. It sounds a little like a large garden tractor at full tilt. Its louder on the cart than when someone else drives it, and its fairly quiet at half or less throttle, near stock sounding at quarter or less throttle. Its a walker quietflow with no tailpipe, which would likely make it quieter. The smaller clones like a smaller header, the gokart places list sizes for stock and modified engines. You can hop that up to 8 or more hp for next to nothing.
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Old 07-11-2013, 10:18 PM   #9
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Default

I was gonna do this exact same thing but I was going to use a 18hp twin. But I found a good deal on a gas cart.

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Old 07-12-2013, 11:51 AM   #10
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Default Re: Small blockin' it, 212 HF

Thanks Sho. I will be looking for a short muffler and then pipe it out the back.

TTCFan, good luck. The laminations were a pain to get off, but I did end up with a pile of copper from it! I expect to get $20 or so when I take it to the recycler. Hopefully the lathe can cut those laminations off easily. I am actually looking to buy small used lathe now from a friend. Let me know how long it took you to get the laminations off. I spent over 2 hours with the torch and angle grinder... it was stupid how long it took.
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