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Old 04-24-2019, 02:55 PM   #1
BlueDubPirate
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Default 2008 CC Carryall Rebuild

I recently purchased a 2008 Carryall that had seen better days. It was used by maintenance in an apartment complex so it was free of the corrosion that comes from working a golf course. I intend to build something to serve dual purposes, 1) to help with projects on my property and 2) something for the Ms. and me to use around town. It will need to be both functional and aesthetically pleasing (or she won't use it, much less ride in it). So off we go. I intend to use this thread to document my progress and probably ask a TON of questions.

The main obvious issues with my cart are the following:

1) The original cargo box was replaced with a flatbed from a 700. Its way too long for the cart. That's gotta go along with the toolbox. I'd like to replace it with a smaller stake-side bed. Looking around now for the parts/kit.

2) Someone replaced the original 10" steelies with 8" wheels resulting in lost speed and a goofy look. Just replaced those today (see pictures below).

3) Suspension and undercarriage: The rear suspension sags, likely due to years of hauling stuff around. Will start with new springs and rear shocks. Those are on order. She'll get a full cleaning on the underside and engine bay.

4) Drive Train: The Kawasaki FE350 motor still seems to run strong, but I want more power, smoother power. Abandoned the rebuild option and ordered a B&S 23hp V-twin swap and new axle gears due to the clockwise/counter-clockwise issue.

5) Exterior: It needs a full cosmetic restoration and all the parts needed to make it street legal (new light kit, LED Bar lights front and back, new windshield, etc). I will keep the front cowl, but repaint it in black. All of the aluminum panels need to be brightened up and the roof will be replaced. Trailer hitch receivers will be mounted front and back and a winch will be added that can be mounted on the hitches (so I can use it in the rear or the front).

6) Interior: New seats, floor, dash, gauges, steering wheel, etc. Last thing I may do is add a stereo system.

I'll keep this updated for anyone interested in following or offering sage advice!



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Old 04-24-2019, 02:58 PM   #2
BlueDubPirate
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Default Re: 2008 CC Carryall Rebuild

New wheels. Went from 18.5x8.5x8 to 22x11x10. The 10" wheels let me stuff meatier tires to improve the ride. They fit in spite of the saggy rear end. Aesthetically, its a big change. I think I picked up a few MPH at top end with the larger tires.

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Old 04-24-2019, 05:32 PM   #3
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Default Re: 2008 CC Carryall Rebuild

Motor arrived today.

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Old 04-25-2019, 06:41 AM   #4
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Default Re: 2008 CC Carryall Rebuild

Looking forward to seeing your build!

I'll be offering peer pressu…..I mean advice when I can.
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Old 04-25-2019, 07:46 AM   #5
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Default Re: 2008 CC Carryall Rebuild

Pretty sure an LS engine would be cool [insert peer pressure here]
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Old 04-29-2019, 10:27 AM   #6
BlueDubPirate
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Default Re: 2008 CC Carryall Rebuild

Extracted the old FE 350 motor over the weekend. It was running very well before it was pulled. So, I have a running FE350 engine, starter/generator, fuel pump, drive and driven clutch that is looking for a good home!







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Old 04-29-2019, 10:32 AM   #7
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Default Re: 2008 CC Carryall Rebuild

Parts table full of goodies for the Carryall. Now working on removing the front cowl and all the trim pieces so it can be sent off to be repainted. I'll be power-washing 11 years of grime from the engine bay before replacing the springs, shocks and putting in the new motor. Also, had to purchase a gear puller to get the driven clutch off of the rear end. That comes Wednesday.

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Old 04-29-2019, 01:13 PM   #8
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Default Re: 2008 CC Carryall Rebuild

Pretty much stripped down and ready for a deep cleaning. That will happen tomorrow. Cowl is on its way to be painted. Two problems I need to solve, 1) how to remove steering wheel and 2) how to get those "Turf 252" stickers off of the aluminum panels without marring the finish (solvent?). And holy cow, does this thing have a lot of "Warning" stickers. They're ugly and I will be spending time with solvent removing them.


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Old 04-29-2019, 01:27 PM   #9
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Default Re: 2008 CC Carryall Rebuild

Looking good and I'll be following your build.

You shouldn't have a problem selling that 350 for anyone looking to upgrade their 290 but wanting to stay stock.

For the steering wheel; go ahead and soak the shaft in PB blaster, Kroil or any other penetrating spray you have and let it sit for a while. Unscrew the nut to the end of the shaft so it's flush with the end to protect the threads and give it a few good wacks with a hammer. Repeat as necessary.

Then using your knees on the back side of the steering wheel with your feet on the dash, pull upwards with your hands and push up with your legs to get the wheel off. Using a deadblow hammer on the backside of the wheel works wonders too. Good luck!
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Old 04-29-2019, 07:20 PM   #10
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Default Re: 2008 CC Carryall Rebuild

Got the steering wheel off thanks to some counter-intuitive advice. The "pound the bolt with a hammer" thing worked! Also planned to change out the rear suspension today but ran into a problem. I ordered the correct rear springs to replace my old, saggy ones but the company sent me the wrong springs! After wasting a lot of time trying to get them installed, I finally realized they were too short. Very frustrating. I'll have to wait 2 days for the clutch puller and 4 more days for my new springs. I'm stuck.
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