G1 clone swap

builtnotboughtg1

A few months ago, I bought a started (but far from finished) g1 clone swap. When I bought it, it had already had the motor put in, clutches set up, lift kit done(had to add to it, though) and quite a chop job done to the rear end. I'll start from the beginning (not many pictures at this point, hadn't thought of making a thread like this yet) the first project was to get the motor running correctly, as for it was running very rough from a long time sitting full of fuel. After that, we ran into and issue with the govenor on the motor. The thing slipped causing the motor to go in to a nearly 10,000 rpm wild run (thank goodness it never slipped into gear ) after days of trying to figure out what was causing it, we discovered the govenor. Reset it, problem solved.

Next project was the shifter. It was in an extremely uncomfortable place between the passengers legs. We built a bracket and stood the shifter up and built an extended arm. Picture to follow.

We built some replacement fender wells to go under the body, the factory ones are MIA

After that, we added the muffler off of a kx250 dirt bike to get less construction hence more power. Custom made header, flex piped to the muffler.


Had to add a couple of large shocks in support of the large monoshock the original owner had added for lift, because the shock inside was no longer a shock, just a holder for the spring. It only remains because it hold the ride height while the other 2 give it suspension.

Built an aluminum skid plate to protect the rear end components

Added 3" of wheel spacer to the back to get the widths nearly the same (still have an extra 2" set if anyone wants to buy them)

Tore out the entire floor including the gussets to replace them. New supports and side channels from scratch. Aluminum floor plates, extended back to make a type of battery tray (have pictures)

After a couple weeks of tinkering around fixing small things and stockpiling parts like king pins and bushings for the front end, and installing them, we had a catastrophic failure we broke an axle. After some searching on the internet, we found brand new axles for $200. It hurt, but at least it was fixable, right? Wrong. Turns out, our rear end had been swapped. We had the reared out of the g2 and up (not the Dana ) and the axle tubes and axles were the g1 style. Which are irreplaceable so we tackled the challenge of lengthening the axle tubes to accept the modern long side axles. No pictures of this, but I can answer questions on how it was done if anyone wants it. This had us down for nearly a month waiting on parts. During this time, we preformed a massive tear down clean up rebuild. I do have a couple of pictures of this.
After recovering from this fiasco, we started having clutch disengagement problems (you may have seen my thread about this) but turns out it's not the clutches fault, it's that the govenor (I've grown to hate that thing) was holding the idle in so high that the idle screw did no good and there was no amount of adjusting would let it go down. So, we built a direct throttle linkage. Detailed pics of this one. Aside from an array of small little projects to get things tuned in just right, that is where I'm at now. I will add more details and pictures as I remember them, and as I progress further in the build. Sorry for the long post, just trying to catch up on what all we've done. I'll post pics in a post below this one!

BGW

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builtnotboughtg1

Okay, it seems to be working now. But it won't do more than one Sorry, I'm new! Haha

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sho305

Sounds like a great project, though maybe a little deeper than you hoped. Would say buy a set of HD valve springs and an advance timing key, both are cheap, that will let your clone run much better at high rpm and not hurt anything with no governor. Though I'd recommend you get a couple tanks of gas through it before you wind it out hard. Also make sure you have the right or better valve retainers, some clones have better ones than others. Stock ones use the button/retainers on both valves. Keep posting, sounds like some great work!

Field6565

Do you have anymore pics? Sounds like an interesting build.

builtnotboughtg1

I have quite a few pictures but I can't figure how to post more than 1 at a time. I'll look into the valves. They do seem a bit loud. When I re adjusted them shortly after getting the cart I found that I couldn't even get a .002 feeler gauge under them. The nearest project is re-jetting the carb. They are in the mail and should be here any day now. It's running lean from the opening of the exhaust and air. Here's a pic of the vertical shifter:

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slonomo

I like this shifter idea.

builtnotboughtg1

When it's finished, it'll have a box around it that fits tight to the body that will have the key and choke. It was simple to do, it's just a piece of 8th inch plate cut the size of the back of the shifter, welded to the middle floor brace. Here's a picture of the skid plate:

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sho305

Some people including me set the lash tight so the rocker just slides around. The gokart guys set them at zero and I get close.

builtnotboughtg1

Where would I get the HD springs and advanced timing key? I can't seem to find them. Do they preform better when tighter, or is it just a preference thing? Here it is when I was mocking it up on the shop floor to check the position if the differential. And one last question, how can I post multiple pictures strait from my device? When I use the 'manage attachment' button it only lets me use 1 at a time.

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turbof250

You can get the springs and key from Vegascarts.com. The springs are tough to install, compressing them takes some effort.