400 ex front suspension and brakes on ezgo txt

tunnelmike

Anything I should know before I start ? Looking to widen the ex frame and use the factory a-arms to achieve the width I need. Thanks for any advice. Mike

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Minnesota_Duane

I'm doing a Z400 Suzuki front on a Workhorse. Do you have a pic of your front end?

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smokindawg

(1) Measure everything and make sure that you have it figured out before you start cutting up the front end to widen it.

(2) Measure everything. Do some research here and other places for thoughts and ideas before you start cutting up the front end to widen it.

(3) Measure everything. Run thru all the ideas you collect and decide what will work, or what fab work your comfortable doing that will work in your situation.

Did I mention to measure everything?

I say it over and over so that you'll make sure and have it all figured out before you make that first cut. You can't undo it once done. Fix it maybe, but it's easier to do it right the first time.

Duane, that looks like it would work good for a cart front end with some mod work.

Be sure to start a new thread so document your work on yours!

tunnelmike

Duane , I could text them to you , but it looks almost identical to yours but different colors. Mine is 6 or so inches narrower than what's on my cart now. Easy fix.
Adapting the Honda disc brakes to work on the ezgo brake pedal will take some work. As will making the two steering systems work together. I know this has been done and I am looking to not make the same mistakes someone else already made. I could figure it out I'm sure , just trying to speed things up a bit.

Smokin , that's what I plan on doing. I'd like to see how others have done theirs and hear what they wished they would have done ! R&D stage now. Thanks for the help and good luck with your project. Mike

Minnesota_Duane

I had 1/2" plate cut for my wheel adapters 7" circle with a hole in the center to clear the hub and I had him burn my bolt patterns 4x144mm and 4x4" 45 degrees apart and 1/4" diameter so I could drill them myself. I used automotive wheel studs for the 4x4" and I drilled and tapped the 144mm 1/2x20 and used allan head cap screws from the inside out on the wheeler hubs (I had to remove the rotor and then bolt it back on). I also had to drill the hubs for the 1/2" bolts. I bought 14" Madjax wheels, they have 1" offset and stick out past the cowl about 2 inches either side. I have 235 60 14s on the front http://www.ebay.com/itm/181724897919...%3AMEBIDX%3AIT
Get the wheels you want before you cut it up.

smokindawg

Sounds like you did well Duane in having your adapters made. I have a mini mill and a DRO. I've been reading on how to set it up to do that as well.

It would be nice to be able too make my own adapters so that I could take advantage of some of the cheap ATV wheels on Craigslist. Also so that I could get a front end with brakes that could be adapted easily by changing the front end.

ATV front suspensions have been used by a few guys here and I'm sure given a little time more of them will speak up.

I started a thread recently about converting/building the front end off a Yamaha Blaster and installing it on my Yamaha G1. I'm building my own spindles to fit using the ones from a G1 and making them fit the ATV A-arms so that I don't have to buy or make adapters. It's starting to come together and I think will work good, but time will tell.

When you start thinking about adapting parts from other machines to these your pretty much on your own for a lot of the build as no two builds will be the same. You can get plenty of help from others here and use others ideas, but in the end, no two will end up exactly alike.

Good luck and be sure too post a thread with lots of pictures. You may be the next one to inspire a build.

Unforgiven

Yes sir there are thing to know,... measure twice cut once,... Well Dawg done covered that.

I took a 300 ex split it down the middle. Added 10 inches, this was a mistake on my part. 8" would have worked for me. Next the stock shocks are probably not work for the cart. I ended up adding 2" lift. Maxed shock out on adjustments. And of course there is that funky bolt pattern on the front that don't match the rear. Other than that I really like the ride on my Honda IFS. Hydraulic brakes work fine. They will stop you, not on a dime but eventually you will stop.

What part of the Hills of Ole Miss you from? Kemper?

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tunnelmike

Magnolia, just south of McComb. It's hill country compared to south Louisiana where I was previously! My cart came with 2" adapters to use atv wheels and I will be using Honda wheels.

Unforgiven, did you mount to the leaf spring mounts on the cart? I plan on using the factory a-arm geometry and adjusting the height by the angle of the tubing connecting to the frame. At least that's the thought ! Still planning and looking for input. I think I can use the rear brake reservoir and mechanism to connect to the ezgo brake pedal with a threaded adjustment to be able to use the ebrake on the cart and the factory brake pedal.

I haven't looked at the steering challenge yet. I've been busy and the rain has been slowing me down. Still looking for input from others to continue planning. Thanks for the help and suggestions. Mike

Unforgiven

I'm a few clicks north of you in Leake co.

Yes you are correct. Both front ends I've done I mounted to the leaf spring bolt pattern with a L4x4x3/8 angle. Also mounted upper supports to points close to the shock mounts.

tunnelmike

4 points of attachment? How did you tie in the brakes? It seems like it won't be to much of a problem. With a plasma cutter and a mig welder I can do plenty ! The frame was apart so I need to clean it up and reassemble to get accurate measurements.

Then I can figure out where it needs to be to get the lift I need to clear 25's and how wide I need to make it. I can eliminate my front wheel spacers and adapters and still use atv wheels.