500 cc 2 stroke 4x4 ezgo

knkyle

This is my 4x4 golf cart. I used 2 golf cart rear ends with Lincoln lockers (one for the front), Polaris tranny and front hubs, arctic cat zr 500 engine with a golf cart drive pulley, and starter/generator, and Polaris rims and tires.

I started this project the beginning of September and just now starting to see the finish line. I should be able to finish with a heated cab for less then $2500. My goal was $1500 or less, but I decided to a machine shop do a lot of the parts that I wanted to be perfect.

When I get it done, I hope to have all the lights, wipers, seat belts, horn, and seats on the back that I can switch out with an electric dump bed. Eventually I plan to try and make it run on HHO (water).

I have two more carts sitting in my hay shed that I want to build someday, this will probably have to wait 4 or 5 years until my kid is old enough to entertain them selves outside though. Hope you like what I have done!

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BGW

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Unforgiven

wow,...keep us updated

I have to ask about the avatar? is that the cart you speak of?

knkyle

No, that is a shrunkette. It is a factory made side x side. It was made for two years, 1984 & 85 then the company went under. It came with a 19 HP Briggs, I was told that it was original when I bought it and then found out it had a lawn mower rear end. Since it wasn't, I put a polaris sport under it with a 300cc engine, and sold it. It was one of my favorite builds, but it was just a toy and I needed money to keep going on my 4x4 golf cart. I lost my butt on that one. It was fun to drive, the back tires were always spinning and all over the place, even with two adults in it.

knkyle

Had another set back today, I found out that the starter/generator doesn't charge when it is ran clockwise. The good thing is that the stator is putting out a good amount of AC current, now I need to find a way to turn that into DC so I can charge my battery since the snowmobile the engine came out of didn't have one.

branson

what did you do to that axle to get front steering. are you using driveshafts or belt drives to get to the axles. it looks pretty cool so far

knkyle

I think I got lucky! I seen on extreme 4x4 a long time a go where they made a steering 12 bolt, and ran it upside down, so that was my plan. when I had it up side down the tires were going opposite directions. I don't know if ezgo made rear ends for electric carts different then gas or what. I just stick with luck on this one.
I have belt drive between the engine and tranny, a chain from the tranny to the drive shaft that runs between the rear ends.
This started out as "going to be my last big project", but now I'm running out of time and now it has become "last big project until my kid is old enough to be outside by their self". I have three weeks until the due date and I hope to have it drivable by then. Even though I am settling on several things to speed up the build, it in by far the best 4x4 cart that I have built.

knkyle

To day I got the shifting linkage figured out and the front half shafts welded and installed. Now found a new problem, When I bought the gears to turn my drive shaft I figured on a top speed of around 45 mph, needless to say, I didn't get it right, It feels like high school all over again. I am lucky if it will get 15 mph. I guess as long as it moves, right. I will put in a jack shaft with a big and small gear on it to try and improve on that later on. Here is some pic's of the half shafts finished and the shifting linkage.

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knkyle

Got my radiator mounted tonight, hopefully Monday night I can get all the hoses ran and a guard built for it.

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snookman19

Personally I think the radiator would get hung up on stuff on the trail. Other ten that it looks great! You should check out the one I'm building.

knkyle

I plan on building a heavy front bumper with an expanded metal guard for the radiator, It will be heavy enough to handle my front end loader, So i'm not too worried about it for now. I'm just trying to get it drivable before my kid is born. I have been able to test drive it a few times, but it's not ready for a road test yet, after I can drive it down the road, Ill take it to my moms house and go crawling through the creek and that will tell me if it is built strong enough. I have checked your build out a couple of times, I hope you can find the transfer case you are looking for so you don't have to turn yours backwards and run a jack shaft from your tranny to the t-case like I might have to do for my starter/generator to get it to turn the right direction to charge if I cant get a rectifier to work with my sled engine. yours looks scary to me because everywhere I go is either high speed down the road or pulling a trailer of firewood through the creek with a lot of side hilling, so I like to have about a foot of ground clearance and center of gravity as low as possible. I thought about buying an old ranger to use but they are too wide and too expensive. I seen where they were talking about calling your cart big foot, but it made me think about the overkill truck. I look forward to seeing it finished and hearing how it handles.