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Old 10-30-2014, 12:24 AM   #1
smokindawg
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Default G2 Rear end in G1!

I'm in the process of putting a G2 rear third member in my G1. I've heard that the axles and tubes would interchange and that the rear would then bolt right into the G1 swing arm.

What I heard was right. It did bolt right in but the driven clutch is touching the swing arm and I'll have to bolt the engine farther to the left.

I've seen a couple other rear end changes but one changed the complete swing arm, the other just changed the bolting of the rear and used the G2 axles and tubes.

Has anyone done as I did? If so, what did you do to allow clearance for the driven clutch. Also, now I'm not sure the drive clutch will clear the frame since I have to move it over.

I may be able to make it work with the drop I'm going too build into the swingarm mount. I may also have to bend in the swing arm to help with clearance like done on the frame when lifting the G1.

We'll see how it works out. Any other suggestions or ideas would be appreciated.
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Old 10-30-2014, 05:46 AM   #2
Field6565
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Default Re: G2 Rear end in G1!

I'm not sure what you have going on here. Is there anyway you can get some pics of it?
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Old 10-30-2014, 08:27 AM   #3
Downeydirt86
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Default Re: G2 Rear end in G1!

I have done the same swap in my g1 and i just pulled out the old sledge hammer and hit the tube right where it was contacting the driven clutch and it has barley any clearance now after a few hits but it fits and has worked fine off roading hard for 3 years now no issues. you will also have to cut the front mount or bend it if i remember right. i dont think i even used the front mount and i have had a 420cc engine again no issues no movement at all since its held together mainly with the axle tubes which are bolted to the swing arm.
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Old 10-30-2014, 08:48 AM   #4
smokindawg
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Default Re: G2 Rear end in G1!

Downey, that's what my plan is. I'll heat the tube and then dent it like I did the frame when I built the lift for the cart. I knew that would take care of the driven clutch problem. Your correct about the two mounts that bolted to the original differential. They won't work anywhere. I'm cutting them off today and will make one to weld in their place. I'd just feel better if there was one connection point.

I also need to come up with the shift linkage that fastens to the differential. I didn't get any of the shifting parts. But I'm going to try to make my own single cable shifter using a push/pull cable and shifter from a boat setup.

I haven't started on the engine and drive clutch as it's still in the cart on the original swing arm. I'm using the original drive clutch so won't know till I set the engine on this swingarm if it will clear the frame.

Field, I will get a picture of the rear and clutch mounted to the swing arm today, but can't get engine installed pictures until I get to that phase. I may be worried about nothing, but it looks like it's going to be very close.
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Old 10-30-2014, 05:25 PM   #5
Cvans
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Default Re: G2 Rear end in G1!

In my application it was necessary to cut the axle tubes and axles. None of the bolt holes on the G2 differential lined up with the frame and the differential had to be rotated slightly. I think I used the G1 axles and tubes on the G2 differential. Thought I had a photo but I'm not finding it.
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Old 10-30-2014, 06:53 PM   #6
LURCH
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Default Re: G2 Rear end in G1!

Quote:
Originally Posted by smokindawg View Post
I'm in the process of putting a G2 rear third member in my G1. I've heard that the axles and tubes would interchange and that the rear would then bolt right into the G1 swing arm.

What I heard was right. It did bolt right in but the driven clutch is touching the swing arm and I'll have to bolt the engine farther to the left.

I've seen a couple other rear end changes but one changed the complete swing arm, the other just changed the bolting of the rear and used the G2 axles and tubes.

Has anyone done as I did? If so, what did you do to allow clearance for the driven clutch. Also, now I'm not sure the drive clutch will clear the frame since I have to move it over.

I may be able to make it work with the drop I'm going too build into the swingarm mount. I may also have to bend in the swing arm to help with clearance like done on the frame when lifting the G1.

We'll see how it works out. Any other suggestions or ideas would be appreciated.

Hey Bud, you going to get that mess of parts you got from me put together sometime??????
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Old 10-30-2014, 08:30 PM   #7
smokindawg
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Default Re: G2 Rear end in G1!

Cvans, your right, the bolt holes for the rear won't line up on the G2 unless you use the axles from the G1.

I got it to line up using this setup but will have to dimple the frame to clear the driven clutch.

Lurch, I'm working on it. I have a G2 now that I got for the build. I just need to pick up a new crank for the engine and a driven clutch as the one on the G2 is bad.

But I'm getting closer.
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Old 11-05-2014, 09:40 AM   #8
smokindawg
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Default Re: G2 Rear end in G1!

Here is the swing arm! Just enough to squeeze the belt on.



Notice how close the clutch is to the swing arm tube. I hope that with the engine lined up it will clear the main frame with the swing arm installed.

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Old 11-07-2014, 07:02 AM   #9
gray horse
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Default Re: G2 Rear end in G1!

If you use the axles and tubes from the G1 rear on the G2 3rd member it will put everything in the same place as the G1 rear. I added 3/4"-1" spacers between the swingarm and the rearend to provide enough clearance for the driven clutch. Works great and didn't have to beat/cut the swingarm.
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Old 11-07-2014, 08:58 AM   #10
smokindawg
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Default Re: G2 Rear end in G1!

I'll probably add a spacer block to each side as well. I'd like too get just a little better clearance.

Gray horse, what engine clutch are you using? I still wonder if I'm going to have clearance problems with the factory clutch on mine and the main frame moving it over more with the relocation of the differential.

Did you drop your swing arm in the front?

I know I can make this all work, just like to have a handle on it before I get too deeply into it.
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