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Unread 02-05-2015, 09:30 PM   #21
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Default Re: Tube Frame Workhorse Big Block

Nice work Titan, please keep on with your story and pictures!!
Very interesting!!
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Unread 02-06-2015, 05:37 AM   #22
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Default Re: Tube Frame Workhorse Big Block

It's pedal placement time!

Needed to do a little fitting and notching for the brake pedal and support bracket. This is the EZGO stock pedal. I have Ausco cable operated disk brakes for the rear that will be installed later. After the tube was notched for clearance another piece of tube was welded in to give some strength back. With a bit of massage work the parking brake will work like it should. This pedal also has the switch to operate the brake lights. Speaking of which, I found some LED tail lights at the parts store to use. I think they will look good in flush mounted in the rear fenders.

Any way it is now time to start placing the long travel front assembly. This is a Stretch Plastics that my previous Workhorse wore. As you can see I have been operating on it. It will be welded in instead of bolted like it came stock.

Oh and here is one of the donor workhorse, may she live on!
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Unread 02-06-2015, 09:38 AM   #23
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Default Re: Tube Frame Workhorse Big Block

What type tubing notcher are you using?

That is some clean work in building that frame.

You definitely have skills. I bet your well liked where your living with those skills too.
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Unread 02-06-2015, 07:01 PM   #24
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Default Re: Tube Frame Workhorse Big Block

Dawg,
The notcher is the NotchMaster from JD2 https://www.jd2.com/p-63-notchmaster.aspx I am pleased with it. I had a Harbor Fright special before and while you could make a notch it was not as well built and tended to let the hole saw get away and eat its self up. With the JD2 I have around 100 notches on the same hole saw.

I do get visitors to the shop and quite a few work requests. I spent last fall repairing combines. Most of the folks here have not seen a dune buggy or golf cart, so at this point they are not sure what I am building.
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Unread 02-06-2015, 07:58 PM   #25
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Default Re: Tube Frame Workhorse Big Block

Very nice work!
I was looking at tubing benders recently and the JD2 was one of the top three. Their notcher is super nice too.
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Unread 02-06-2015, 08:01 PM   #26
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Default Re: Tube Frame Workhorse Big Block

They do make some nice tools from what I see on the site, as well as what I see you've done with them.

I bet the people that see your build are scratching their heads!
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Unread 02-07-2015, 08:36 AM   #27
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Default Re: Tube Frame Workhorse Big Block

Something to think about when purchasing a notcher. There may be (will be) a time when you want to make a notch in a bend. Can the notcher do this? I had to get creative to get mine to cut in the bend.

Been fussing around with the front suspension and steering on the cart. I have burned many hours on this trying to get how I want it. This is a Stretch Plastics LT kit for the older style of cart that had the rack mounted under the dash that moved a pitman arm that the tie rods were attached to. I needed to not use that style of steering on this cart and to use the more conventional rack and pinion that has the tie rods going directly to the spindles.

Back in 2013 I posted a thread asking for recommendations on steering racks. People were very helpful with info. I chose to go with a Club Car Precedent unit. I got a new rack and the input u-joint for the project.

This has presented a couple of problems. I have it placed where I think it least problematic. This combo is going to have some amount of bump steer. The rack is wider by about 1.5" than the pivot points for the A-arms. Cycling the suspension does cause about 1/8" of to change per side right around what I think the ride height is going to be. The rack can not be cut down and still have the same amount of steering deflection. It would be a bit of work to relocate the A-arm mounts, but doable. One thought is to leave as is and drive it to see if it will be a problem.

When I was setting up the rack mount I used braces in place of the front coil overs to simulate ride height while the cart has been on the fab table. I leveled the lower A-arm (parallel with the ground) as a base point. With the arms in this position it gives about 2" of droop before the arms bind, which should be adequate for how it will be used. From this point the rack was mounted and tie rod sleeves made.

The steering column is welded into position and the shaft that connects the column to the rack was pieced together from EZGO and Club Car parts with a bit of round rod thrown in for good measure.

Well that is it for today!
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Unread 02-07-2015, 02:28 PM   #28
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Default Re: Tube Frame Workhorse Big Block

Looks good!

Just curious as to why you mounted steering on the right side?
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Unread 02-07-2015, 05:56 PM   #29
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Default Re: Tube Frame Workhorse Big Block

Ah Ha! I was wondering if anyone would notice that...

It has been converted to RHD 'cause all the folks here drive on the wrong side of the road! Trying to rewire your brain to drive from the wrong side of the car on the wrong side of the road has had some "interesting" moments.

The RHD is why I thought I needed to use a regular rack and pinion instead of the factory EZGO unit. It would have not been easy flipping it around and such to make work.

My wife could not wait to try it out, so she climbed up on the fab table and found a seat. I think I could hear her making Vrooom vroom noises.
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Unread 02-07-2015, 10:54 PM   #30
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Default Re: Tube Frame Workhorse Big Block

I noticed it right away and had figured that was why you did it that way.

It's the first Right side golf cart I've seen.
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