1976 build thread

[bvilleharleycart]

Hey guys, so a friend of mine suggest I start a build thread for the cart we just got . I'm going to give it a try and follow this all the way through (no guarentees) here is the cart we got 1976 HD three wheel for $150.00. Object is to not go over $500.00 yeah right.



This is what we got. It does run and everything works.






New tires Carlisle Badlands 18x9.50s and boat seats, all from Ebay free shipping on all. Spooned the tires on asap. We live in the mountains of western north Carolina so we needed some tread. Now goes good in snow and mud. Then my wife found another cart on Craigs list. Shes the one that gets me into this stuff.






figured it has a very nice canapy frame and good front clip so that is worth it right there. Got this one for $90.00. Has a 1980 frame and motor and older body style on it. We were planning a parts cart but after checking it out and seeing everything works I thought I would just take what I need and then let my son build a cart to run in the woods. He likes mud and can haul wood for me.Plus this one also came with a box of extra parts ie. gemerator, forward reverse lever a few carbs two nice mufflers blah blah.

The '76 had a terrible leak between the cylinder and the block so it started running terrible so it was time to tear it down. I pulled the engine ordered new piston , rings, seals, gaskets ect. While waiting I started to clean all the oil ( about 1/2 inch thick) off the engine and frame.



We now have lots of pretty parts painted and clear coated.



We also ordered parts for the clutch, new seals , bearing, and little metal pieces that were broken. Found a great guy in Tacoma WA. that sent me all the pieces and even through in the cool almost chrome clutck cover. It is re-built now and will hopefully work like new. Also needed a rear hub, the old one had damaged splines and flopped around on the axle. That is now reaplced and working great. Now to assemble the engine and see how it runs. I'll be back.

[bvilleharleycart]

ok engine is in and it fired right up, no leaks no surprises. Now will run it for a few days and tear down the whole cart. Thanks go out to all the folks here

[smallblock450sl]

I love the color's and attention to detail

[brooklyn]

Its going to sharp for sure bvilleharleycart

[bvilleharleycart]

Ok here we are assembling the engine





have new fan since old one was in a million pieces inside the shroud and blown up into the cylinder. I like the look of polished edges on the head fins. I feel it's best to sand them flat with a palm sander before painting that way you have a nice flat edge to sand after paint. These heads are rounded so the fins tend to be slanted as you go but it worked out great and gives the head that nice motorcycle look.



I used a carb paint from Eastwood supply that is supposed to look like the old Rochester carbs from back in the day (gold colored). I like the effect and it is gas proof.



I went to ace hardware and got some stainless allen bolts to replace the old slotted bolts the hold the fan shroud on . Should make any further removals much easier. They also look cool but you wont see them once engine is installed



A T handle allen wrench now works much better than a screw driver did.



and the new motor mount, this one was shredded and no longer doing its job. Used 3/16 inch rivets, when did they get so expensive??? Like I said we put a little gas in the air filter neck and she fired right up. Runs pretty strong and I said I didn't have any leaks but I do. It appears to be leaking gas some place between the reed valve assembly. I will take that apart and try some sealer on that. Otherwise pretty happy with the engine. I don't have the shroud painted yet because It had some gouges and the casting they used to make it was terrible. I guess cosmetics were not important on golf cart engines. I put some bondo on the gouges and all the terrible scratches and will paint that when it's nice and smooth : ) Sorry for the blurry pictures will try better next time.

[PAPABEAR1]

Looking good . Nice paint job on the engine .

[Craigs carts]

If those are alu. rivets holding the motor mount they won't hold very long.
Love the allen headed bolts I've been doing the same thing. nice looking build keep the pics coming.

[bvilleharleycart]

yes they are aluminum. I was wondering that. They didn't have the size I wanted in steel. Thanks will try to keep on rolling here

[bvilleharleycart]

Ok guys here is where we're at now. The leak is coming from the crankcase seal or lack of gasket. We removed the engine again and applied air to the sparkplug hole and it is leaking all over on the bottom. I will get some more parts ordered and hopefully ba back soon. Just a minor setback and now I can replace the inner crankshaft seal while inside. Wish me luck.

[KillerCC]

Anymore progress? I'm not a harley GC fan, but I have a friend who just gave me a 3 wheeler and thought I'd look over here to get some ideas. I love the detail you put into the engine! I can tell by the pic of your hands that you've probably been doing this kind of thing for awhile. Keep up the great work.