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Unread 04-11-2015, 08:08 AM   #31
Getting Wild
Yamaha
 
Join Date: Feb 2015
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Default Re: 3 Cyl Yanmar in a G16

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Originally Posted by UncleJerm76 View Post
I just used the exact same metal lathe to make some sleeved nuts out of collar nuts (finished collar nut on right). Great little machine.
Yes it is a great little machine but little is a relative thing here, as one of the smaller Pacemakers it's still weighs over 4 tons.

I struck out on the bolts yesterday and I have some side work to get out of the shop today but I hope to at least get the adapter counter bored, get or make the needed bolts and get the motor mounts welded in.
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Unread 04-11-2015, 07:28 PM   #32
Getting Wild
Yamaha
 
Join Date: Feb 2015
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Default Re: 3 Cyl Yanmar in a G16

It was a busier day than I expected so I didn't get much time in the shop to work on the Yanmarha.

I found some button head bolts and got the holes for the adapter counter bored so now the bolts are flush. I got the clutch re-mounted and now have the engine where I want it. I have the alignment as good as its going to get. Now I have to tack the engine mounts to the plate, remove the engine and then weld it all up. I'm making progress but it's slow going right now.
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Unread 04-13-2015, 06:21 PM   #33
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Default Re: 3 Cyl Yanmar in a G16

So I got a little time in the shop this afternoon and got some things done. I finished mocking up the motor mount and got it all welded up. I put the swing arm and rear axle back in the cart and installed the motor. Its all bolted down and the belt alignment is good, not to mention that the engine fits well in the cart and I have a fair amount of room.

Now for the list of things to do:

1. fuel system. This cart has no fuel tank. I'm not sure how big the stock G-16 tank is but I'm not sure if it will fit with this motor installed. If someone cah show me a pic of a stock fuel tank looking down from the top, I can decide if I should try and find a stock tank or build one to fit the space I have.

2. Exhaust system. I need to ben up some pipe and see if I can route a dual exhaust system that utilizes the Harley Sportster mufflers that I have.

3. Cooling system: I plan on mounting the radiator up front and cutting the front body and making a grill for air flow. I need to run hoses from the engine compartment up front to the radiator. This might present some challenges as the water outlets from the motor are facing aft.

4. Electrical system: I plan on cutting everything out and starting from scratch since I have to deal with glow plug relays and a whole different type of charging system.

The list get longer than that but I'll focus on these things until I get them done. Oh yeah, I have to weld in the new SS battery box that I made.
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Unread 04-13-2015, 10:07 PM   #34
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Default Re: 3 Cyl Yanmar in a G16

Think I would use hydraulic line or copper pipe for coolant lines, if I could route them to the front in a safe place.
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Unread 04-14-2015, 07:48 AM   #35
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Default Re: 3 Cyl Yanmar in a G16

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3. Cooling system: I plan on mounting the radiator up front and cutting the front body and making a grill for air flow. I need to run hoses from the engine compartment up front to the radiator. This might present some challenges as the water outlets from the motor are facing aft.
Radiators are typically mounted in the front, but give some thought to mounting it in the rear bag-well. Cut out the bag-well firewall and flush mount the radiator right there. Once you get the fan mounted it will be pulling fresh air from under the cart through the engine bay helping keep it all cool. The warm air from the engine inst enough to worry about - any decent radiator with a fan would easily cool it down to the desired temp. Its a Lot less plumbing and no worrisome lines running from front to back to cut or damage when having fun off road. Easier to check/fill water as well.
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Unread 04-14-2015, 07:23 PM   #36
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Default Re: 3 Cyl Yanmar in a G16

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Radiators are typically mounted in the front, but give some thought to mounting it in the rear bag-well.
I certainly looked at that but I don't have enough clearance to mount the radiator fixed to the frame and still allow enough clearance for the swing arm to travel the full suspension amount.

I removed the front body panel and mocked up the radiator mount up front. Since the body is already fractured and I would have to repair it, I am going to opt to cut out the fractured area and mount the radiator up front and make a grill to cover the radiator and the cut out section of the front body panel.

I also need to stretch the front end out 2" for tire clearance. I plan on cutting the 2 frame tubes and inserting a 2" extension piece. I will add and additional cross member to tie in to the steering box mounts.

I made up some cardboard templates to make a fuel tank as I really don't think that I have enough room to install a stock G-16 tank. I will cut and bend up some aluminum to make the tank at lunch tomorrow and see how it fits, just looking at how much room I have for a tank, it looks like it might be about 2-1/2 gallon tank.

I find myself sitting on a stool looking at the cart with a beer in my hand trying to figure out my next move, does that count as engineering time and does that count against the man hours spent on this build or is it counted as recreational hours and not counted against the build time? Maybe some of you that have been down this road before can weigh in on this time ruling.

My side work load is building up and the weather id looking good so it ay be a few days before I can get some time to spend on my cart build, please stand by.
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Unread 04-15-2015, 07:43 AM   #37
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Default Re: 3 Cyl Yanmar in a G16

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I certainly looked at that but I don't have enough clearance to mount the radiator fixed to the frame and still allow enough clearance for the swing arm to travel the full suspension amount.
I attached a photo where I threw your radiator on the back of web photo to show you the location I was referring to. Its the bagwell firewall and it shouldn't interfere with suspension travel at all. Obviously you would dress this up a bit and throw a fan on it, but at least it better shows what I did a poor job of conveying yesterday
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Unread 04-15-2015, 07:54 AM   #38
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Default Re: 3 Cyl Yanmar in a G16

For the radiator, having easy access to open air is key.

Up under the front cowl is very tight and air can only get passed from underneath. You would want some kind of air deflector to direct air into that area. Natural air flow is the best, even with a fan. Maybe if you had some air intake holes in the front, some kind of scoop? Sometimes in tight spaces the hot air just gets recirculated and cooling is less efficient.

The rear is better because it can get air from multiple directions. The fan can draw air down from the top, sides, and bottom. A screen/cover can be made for the rear to keep debris/mud out. Mounting the radiator at a slight angle might be needed for clearance. Just my thoughts.

This build is very cool btw!
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Unread 04-15-2015, 01:50 PM   #39
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I tried fitting the radiator in the back last night but it just won't fit and leave room for the swing arm to travel.
If you look at the 2nd pic in my last post, you can see that my front cowl is cracked. I plan to cut that whole recessed area out and make a tubular grill for airflow to the radiator.

I will be stretching my whole front frame 2" to allow for tire clearance and that will give me plenty if room for the radiator and fan, not to mention that the grill look pretty cool.
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Unread 04-15-2015, 02:23 PM   #40
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Default Re: 3 Cyl Yanmar in a G16

Cool project.I am curious what amount of rpms will your diesel be running at?
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