Workhorse chop top

tonyton · 06-10-2009, 10:25 PM

If anyone out there has, or had, a top for a workhorse they probably have had a problem with top supports. They have a lot of sway from having the rear mounting points behind the seat. They usually break at the top mounting bolt.
I like having a top and was going to reinforce it some way.
When I reinforced and shortened the back supports I didn't know of BGW. There are no photos, so I can explain that part. My stock supports broke in the rear under the seat at the top mounting bolts. I took them out and cut out the broken section. 1" above and 1" below the broke bolt hole to create a 2" drop. I found a section of steel tube that fit inside the original tube.I cut the small tube to the max distance that would fit in the removed are. So theres an 18" steel tube inside the outer tube. Welded the joint that enclosed the support rod. Drilled a new hole and it was ready to go.
The back of the roof is now 2" shorter and stronger.

The front support was a different issue. I wanted to have the standard window fit without cutting it. The only answer to that was to tilt the windsheild to keep it and drop the top 2". I moved the mount forward onto the bumper. Welded it to the bumper and....The roof is done . I'm going to shorten the upper speaker boxes and clean up the wiring.
I still plan a support for the windshield frame from the top bumper bolt to the back of the lights. This is what it looks like...I'll post pics of the supports tomorrow

I think it's more like a 3" drop. I'm only 5'9" in heels

Perfect for me

dirtysouth · 06-10-2009, 10:36 PM

Nice work Tony.

tonyton · 06-10-2009, 10:40 PM

Thanks Dirty,
That's why you rarely see a top on a workhorse!

dirtysouth · 06-10-2009, 10:42 PM

Quote:

Originally Posted by tonyton

Thanks Dirty,
That's why you rarely see a top on a workhorse!

Yeah, ya got a point there... I have a '97, I made top supports for it, 'cause it came without a top... It makes sense now...

scottyb · 06-10-2009, 10:58 PM

The shorter top looks Sporty

Think the wieght of the boom boxes is working the top a little harder than stock? I built a rear suport for my workhorse but it has been abandoned in the current makeover.... See if I can find a pic of the set up I built. It was all above the frame and bolt on.... Every cart needs some kinda roof in So Cal.

tonyton · 06-10-2009, 11:16 PM

The speakers do weigh a bit, but sure sound good.

I had a problem before those...then it got worse. The extra front support should help some too. I ran out of time today.
I would like to see an upper side mounted rear support.

The stock are too flimsy. These are a lot better, but the higher the mount, the less the flex.

I lived in So Cal. ITS HOT! The humidity here sucks.....lots of sweat. We both need tops on ours, we use 'em!

scottyb · 06-11-2009, 08:09 AM

I am thinking of building a roll bar that would allow the stock top to mount up....

pbillyi69 · 06-11-2009, 08:56 AM

hey with those big speakers on there how is the plastic hloding up? I had to invert the rear supports because the plastic is breaking all the way around the aluminum channel that goes in the plastic groove i have a 91 cc.... your top looks good....i was thinking of lowering mine 2-3" as well just because.....

ruredy · 06-11-2009, 09:44 AM

I see/seen bunches of workhorses with tops, it's not a real requirement that course maintenance carts have a top on them. matter fact tops are a pain in the butt in general when use for that. They had changed the workhorses rear top mounts years ago but the early ones seem to be almost an after thought with their design. those bars are the longest part on a workhorse besides the frame, they're almost 6' long. Ezgo has shipped them to me in 4' wide x 5' tall x 1' deep boxes, you should see the fedx guy trying to carry them

They will fatigue and break but it takes years of abuse for that to happen, they're not as flimsy as some would have you believe. I've carried all kinds of stuff strapped to mine from ladders, wood, even a queen size bed, the kids use it like a jungle gym and still haven't broke it.

dock98 · 06-11-2009, 09:47 AM

nice work.thanks for the pics.
"in heels".would you mind clarifying that?lol

06-10-2009, 10:36 PM	#2
dirtysouth Gone Wild Join Date: Feb 2009 Location: P-COLA Posts: 1,176	Re: Workhorse chop top Nice work Tony.

06-10-2009, 10:40 PM	#3
tonyton Gone Wild Join Date: Jan 2009 Location: Alabama Posts: 2,120	Re: Workhorse chop top Thanks Dirty, That's why you rarely see a top on a workhorse!

06-10-2009, 11:16 PM	#6
tonyton Gone Wild Join Date: Jan 2009 Location: Alabama Posts: 2,120	Re: Workhorse chop top The speakers do weigh a bit, but sure sound good. I had a problem before those...then it got worse. The extra front support should help some too. I ran out of time today. I would like to see an upper side mounted rear support. The stock are too flimsy. These are a lot better, but the higher the mount, the less the flex. I lived in So Cal. ITS HOT! The humidity here sucks.....lots of sweat. We both need tops on ours, we use 'em! Last edited by tonyton; 06-10-2009 at 11:26 PM.. Reason: need for top

06-11-2009, 08:09 AM	#7
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Workhorse chop top I am thinking of building a roll bar that would allow the stock top to mount up....

06-11-2009, 08:56 AM	#8
pbillyi69 shut up & hang on Join Date: Jun 2009 Location: gladstone, or Posts: 1,168	Re: Workhorse chop top hey with those big speakers on there how is the plastic hloding up? I had to invert the rear supports because the plastic is breaking all the way around the aluminum channel that goes in the plastic groove i have a 91 cc.... your top looks good....i was thinking of lowering mine 2-3" as well just because.....

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06-11-2009, 09:44 AM	#9
ruredy Born Wild Join Date: Mar 2007 Location: Clover SC. Posts: 5,552	Re: Workhorse chop top I see/seen bunches of workhorses with tops, it's not a real requirement that course maintenance carts have a top on them. matter fact tops are a pain in the butt in general when use for that. They had changed the workhorses rear top mounts years ago but the early ones seem to be almost an after thought with their design. those bars are the longest part on a workhorse besides the frame, they're almost 6' long. Ezgo has shipped them to me in 4' wide x 5' tall x 1' deep boxes, you should see the fedx guy trying to carry them They will fatigue and break but it takes years of abuse for that to happen, they're not as flimsy as some would have you believe. I've carried all kinds of stuff strapped to mine from ladders, wood, even a queen size bed, the kids use it like a jungle gym and still haven't broke it.

06-11-2009, 09:47 AM	#10
dock98 doin it in the desert Join Date: Dec 2008 Location: Sonora Desert,Az Posts: 5,603	Re: Workhorse chop top nice work.thanks for the pics. "in heels".would you mind clarifying that?lol

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