96 carry all 2 restoration.

tony357 · 10-02-2018, 08:23 PM

My cart was a sandy victim finally getting around to repairing it. I have ordered duromax 18hp electric start engine to make a swap. using a taper adapter on the 1 inch shaft not sure yet if I have to cut shaft shorter engine not here yet.
Using the original drive clutch with V pulley. I am going to try and mount mini 1 wire alternator where the starter/generator would have mounted rated at 35 amps.
Adding lights, turn signals and horn to cart. it did not have them before. I ordered led tail lights stop,turn,brake and reverse lights.
I am using aftermarket hot rod turn signal switch that will mount on steering column.

Also ordered carbon fiber custom dash once I saw it had to have it.

ill post pics of project as I go along.

tony357 · 10-03-2018, 07:36 PM

Well, I cannot post pics yet.
Tonight the engine arrived VIA Fedex, Gas tank dented in as a lot of other people mentioned in feedback.
I drilled and cut off the crank snout to length I need to reuse club car clutch and tapped the hole to the 3/8-24 thread for the bolt.

Do not try and cut one of those crank snouts with cut off saw I tried Cobalt blade US made and will not touch it. Had to use cut off wheel.

The cone worked very well true test will be when driving.

drilled new mounting holes in motor plate a longer belt will be needed for this project.

tony357 · 10-08-2018, 03:17 PM

taper adapter I used to install club car clutch assembly. I did have to cut carnkashaft snout shorter for application.

tony357 · 10-08-2018, 03:30 PM

Adapter on crank, ultimately for my use spacer that comes with adapter was not used.

Taped off seal to protect from hot debris while cutting off snout.

crank snout cut off.

tony357 · 10-08-2018, 03:35 PM

The crank shaft snout also had to be drilled and tapped before cutting it off. Had to drill one inch into snout before cutting then tapped it after cutting snout off.

Put correct size bit to tap 3/8-24 into snout threads marked it one inch with tape then drilled it out.

tony357 · 10-08-2018, 03:37 PM

chevy mini alternator I am using single wire hook up. sunday I started making up brakets to mount alt.

BBBHC · 10-09-2018, 07:36 AM

Cool build! Looking forward to seeing your progress!

tony357 · 10-10-2018, 06:03 PM

Parts have been rolling in last couple days. Mounted key switch, switches, power supply's and volt gauge into dash.

tony357 · 10-13-2018, 07:07 AM

wired power to the switches, ground to led back light in switches and key switch ground.

tony357 · 10-14-2018, 07:21 PM

Installed tail lights today and ran wiring.

Installed brake switch mounted in frame.

used reverse micro switch to turn on reverse lighting.

wiring run to dash for power and turn signals.

10-02-2018, 08:23 PM	#1
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67	96 carry all 2 restoration. My cart was a sandy victim finally getting around to repairing it. I have ordered duromax 18hp electric start engine to make a swap. using a taper adapter on the 1 inch shaft not sure yet if I have to cut shaft shorter engine not here yet. Using the original drive clutch with V pulley. I am going to try and mount mini 1 wire alternator where the starter/generator would have mounted rated at 35 amps. Adding lights, turn signals and horn to cart. it did not have them before. I ordered led tail lights stop,turn,brake and reverse lights. I am using aftermarket hot rod turn signal switch that will mount on steering column. Also ordered carbon fiber custom dash once I saw it had to have it. ill post pics of project as I go along.
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67

10-03-2018, 07:36 PM	#2
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67	Re: 96 carry all 2 restoration. Well, I cannot post pics yet. Tonight the engine arrived VIA Fedex, Gas tank dented in as a lot of other people mentioned in feedback. I drilled and cut off the crank snout to length I need to reuse club car clutch and tapped the hole to the 3/8-24 thread for the bolt. Do not try and cut one of those crank snouts with cut off saw I tried Cobalt blade US made and will not touch it. Had to use cut off wheel. The cone worked very well true test will be when driving. drilled new mounting holes in motor plate a longer belt will be needed for this project.
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67

10-08-2018, 03:17 PM	#3
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67	Re: 96 carry all 2 restoration. taper adapter I used to install club car clutch assembly. I did have to cut carnkashaft snout shorter for application.
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67

10-08-2018, 03:30 PM	#4
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67	Re: 96 carry all 2 restoration. Adapter on crank, ultimately for my use spacer that comes with adapter was not used. Taped off seal to protect from hot debris while cutting off snout. crank snout cut off.
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67

10-08-2018, 03:35 PM	#5
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67	Re: 96 carry all 2 restoration. The crank shaft snout also had to be drilled and tapped before cutting it off. Had to drill one inch into snout before cutting then tapped it after cutting snout off. Put correct size bit to tap 3/8-24 into snout threads marked it one inch with tape then drilled it out.
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67

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10-08-2018, 03:37 PM	#6
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67	Re: 96 carry all 2 restoration. chevy mini alternator I am using single wire hook up. sunday I started making up brakets to mount alt.
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67

10-09-2018, 07:36 AM	#7
BBBHC Gone Wild Join Date: Jul 2018 Location: Central Ohio Posts: 1,720	Re: 96 carry all 2 restoration. Cool build! Looking forward to seeing your progress!

10-10-2018, 06:03 PM	#8
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67	Re: 96 carry all 2 restoration. Parts have been rolling in last couple days. Mounted key switch, switches, power supply's and volt gauge into dash.
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67

10-13-2018, 07:07 AM	#9
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67	Re: 96 carry all 2 restoration. wired power to the switches, ground to led back light in switches and key switch ground.
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67

10-14-2018, 07:21 PM	#10
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67	Re: 96 carry all 2 restoration. Installed tail lights today and ran wiring. Installed brake switch mounted in frame. used reverse micro switch to turn on reverse lighting. wiring run to dash for power and turn signals.
tony357 Not Yet Wild Join Date: Oct 2018 Posts: 67

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