The G1. Again!

smokindawg · 10-28-2014, 08:12 PM

Well, I'm at it again. Working on the old G1 that I converted to a 4 stroke when I installed an 8hp Briggs.

It's still running good but I hate not having reverse. I also did a hurry up job on it when I installed the engine. I've had breakage problems with the exhaust and had the starter/generator bracket break too. Also when I built the lift I ended up with a pretty extreme angle on the swing arm.

So today I decided to start installing a G2 third member I got recently. I pulled the swing arm out of another G1 I have and pulled the rear end off it. I then pulled the axle tubes, brakes and axles as well as the driven clutch off that rear and installed it all on the G2 rear end. It all fit perfectly and I'm now ready to put it back on the swing arm. But first I need to clean the swing arm up both from grease and taking the fuel line off it as well.

The lift I built ended up being about 12" (I didn't know what I was doing when I built it) so I need to drop the swing arm a few inches. I'm thinking I'll probably drop it 4" and back 4" as well. That should help with the angle on it.

I'll then make a new engine cradle and realign everything. I also need to work on the exhaust again as well. Plus I'll be doing some wiring to hook up all the lights I have on it. So I'll be adding a fuse block for those and other accessories.

I have a few starting pictures of the removal and will take some more as I work on the new swing arm and rear end.

Have my own golf cart lift!

Works great for working under the cart.

Motors out.

smokindawg · 10-28-2014, 08:53 PM

A couple more pictures.

Swing arm, rear and engine all removed from the parts cart.

smokindawg · 11-02-2014, 11:48 PM

Ok, here are a few more pics as I'm building the new swingarm up. I have the rear end figured out and have dimpled it so that the driven clutch will clear. I also cut all the tabs off and cleaned the swingarm up.

The plan is to end up with a 5" down and 4" back. I'm dropping it that much due to the height of my lift. I also intend on making and installing decent engine/rear differential pans/guards to protect things. Just to be safe.

smokindawg · 11-05-2014, 12:28 AM

I'm searching for ideas on just how I want to go about lowering and moving back the swing arm.

Can anyone give me examples of how they did theirs? Again, I want to drop mine 5" and shift it back 4".

I was thinking cut off the original mounts and then weld square tube to the cross member using that to drop the swing arm a bit while also moving it part way back and then pick up the rest with the mounts themselves.

Thanks in advance for any of your ideas.

smokindawg · 11-09-2014, 07:19 PM

Well you all aren't much help.......... LOL, just kidding. I have been reading a lot and while no one has commented here, I took a lot of what others have done and made it my own. It's hard for anyone to give the absolute way too drop and pull back the swing arm.

No one uses the same materials so the process won't always be the same.

I did go ahead and pull the engine, rear and swing arm today and start fab work on the change. I have the parts pretty much figured out for about 4" back and 5-6" down. I made pattern mounts out of cardboard and have them ready to cut from steel. I'll box them for strength and weld them to the cross piece I'm installing where the old mounts were. I didn't take any pictures today but will get some tomorrow as I do more work on it.

I hope to have the swing arm remounted tomorrow and get started on the engine cradle. I'll also have to install another passenger side brake cable on the driver side.

smokindawg · 11-16-2014, 11:54 PM

Worked on the cart some more today and got a lot accomplished. I got the swing arm fit to the new mounts and then got the engine cradle all welded in as well as the mount for the starter/generator.

I heated the frame more and made the extra clearance I needed for the clutch since I had to move the engine over some more. It's all looking pretty good. A couple more days and some heat so I can paint it all and I'll be ready to roll again. I am still waiting on the linkage for the shifting that I'm getting.

smokindawg · 11-18-2014, 01:08 AM

Even with wind chill down around 0, I got some done on the cart. Fired up the heater and got the swing arm cleaned up and painted as well as the new swing arm mounts in the cart. I'm ready too install the swing arm back in the cart and get the brake cables back in as well.

I also got the forward/reverse linkage for the differential can can start building the shifter and push/pull cable to get my reverse back.

I'll take and post some pictures tomorrow as I begin putting the cart back together.

smokindawg · 11-18-2014, 06:45 PM

I have the swing arm painted and installed back in the cart. I'm working on a shifter now. It will be made from the shifter made for a boat motor. I just separated the double and will use only one to shift the rear from forward to reverse using the push/pull cable. It should work very well once I figure out the brackets I need to have to hook it all up.

Pictures of the swing arm painted and installed.

I'll be posting more pictures as I start hooking up and installing the shifter.

meangreenmachine72 · 11-18-2014, 06:55 PM

It's going to be well worth it when you are done. Enjoy seeing the pictures. I have 2 bad shape G1's and a 1984. My son and I enjoy working on them, our Cc Ds was stock and we just finished that one. I am going to pm you if you don't mind. I have a question for you. Going down to 20 tonight no garga tonight.

smokindawg · 11-19-2014, 11:36 PM

I was at it again today. I made a mount and fit the linkage on the boat control cable on the rear and mounted the shifter. It looks pretty good but I may have to do a little bit of changing to make it work like I want. It does shift the rear like it should but being used it needs some tweaking. I do want to dress it up some too.

Such is the nature of being a cheap azz and build using the materials at hand and don't spend much. I may not make the cleanest looking machine, but can do so on a pretty cheap budget most the time.

10-28-2014, 08:12 PM	#1
smokindawg Gone Wild Join Date: Sep 2012 Location: Missouri Posts: 2,755	The G1. Again! Well, I'm at it again. Working on the old G1 that I converted to a 4 stroke when I installed an 8hp Briggs. It's still running good but I hate not having reverse. I also did a hurry up job on it when I installed the engine. I've had breakage problems with the exhaust and had the starter/generator bracket break too. Also when I built the lift I ended up with a pretty extreme angle on the swing arm. So today I decided to start installing a G2 third member I got recently. I pulled the swing arm out of another G1 I have and pulled the rear end off it. I then pulled the axle tubes, brakes and axles as well as the driven clutch off that rear and installed it all on the G2 rear end. It all fit perfectly and I'm now ready to put it back on the swing arm. But first I need to clean the swing arm up both from grease and taking the fuel line off it as well. The lift I built ended up being about 12" (I didn't know what I was doing when I built it) so I need to drop the swing arm a few inches. I'm thinking I'll probably drop it 4" and back 4" as well. That should help with the angle on it. I'll then make a new engine cradle and realign everything. I also need to work on the exhaust again as well. Plus I'll be doing some wiring to hook up all the lights I have on it. So I'll be adding a fuse block for those and other accessories. I have a few starting pictures of the removal and will take some more as I work on the new swing arm and rear end. Have my own golf cart lift! Works great for working under the cart. Motors out.

10-28-2014, 08:53 PM	#2
smokindawg Gone Wild Join Date: Sep 2012 Location: Missouri Posts: 2,755	Re: The G1. Again! A couple more pictures. Swing arm, rear and engine all removed from the parts cart.

11-02-2014, 11:48 PM	#3
smokindawg Gone Wild Join Date: Sep 2012 Location: Missouri Posts: 2,755	Re: The G1. Again! Ok, here are a few more pics as I'm building the new swingarm up. I have the rear end figured out and have dimpled it so that the driven clutch will clear. I also cut all the tabs off and cleaned the swingarm up. The plan is to end up with a 5" down and 4" back. I'm dropping it that much due to the height of my lift. I also intend on making and installing decent engine/rear differential pans/guards to protect things. Just to be safe.

11-05-2014, 12:28 AM	#4
smokindawg Gone Wild Join Date: Sep 2012 Location: Missouri Posts: 2,755	Re: The G1. Again! I'm searching for ideas on just how I want to go about lowering and moving back the swing arm. Can anyone give me examples of how they did theirs? Again, I want to drop mine 5" and shift it back 4". I was thinking cut off the original mounts and then weld square tube to the cross member using that to drop the swing arm a bit while also moving it part way back and then pick up the rest with the mounts themselves. Thanks in advance for any of your ideas.

11-09-2014, 07:19 PM	#5
smokindawg Gone Wild Join Date: Sep 2012 Location: Missouri Posts: 2,755	Re: The G1. Again! Well you all aren't much help.......... LOL, just kidding. I have been reading a lot and while no one has commented here, I took a lot of what others have done and made it my own. It's hard for anyone to give the absolute way too drop and pull back the swing arm. No one uses the same materials so the process won't always be the same. I did go ahead and pull the engine, rear and swing arm today and start fab work on the change. I have the parts pretty much figured out for about 4" back and 5-6" down. I made pattern mounts out of cardboard and have them ready to cut from steel. I'll box them for strength and weld them to the cross piece I'm installing where the old mounts were. I didn't take any pictures today but will get some tomorrow as I do more work on it. I hope to have the swing arm remounted tomorrow and get started on the engine cradle. I'll also have to install another passenger side brake cable on the driver side.

Today
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11-16-2014, 11:54 PM	#6
smokindawg Gone Wild Join Date: Sep 2012 Location: Missouri Posts: 2,755	Re: The G1. Again! Worked on the cart some more today and got a lot accomplished. I got the swing arm fit to the new mounts and then got the engine cradle all welded in as well as the mount for the starter/generator. I heated the frame more and made the extra clearance I needed for the clutch since I had to move the engine over some more. It's all looking pretty good. A couple more days and some heat so I can paint it all and I'll be ready to roll again. I am still waiting on the linkage for the shifting that I'm getting.

11-18-2014, 01:08 AM	#7
smokindawg Gone Wild Join Date: Sep 2012 Location: Missouri Posts: 2,755	Re: The G1. Again! Even with wind chill down around 0, I got some done on the cart. Fired up the heater and got the swing arm cleaned up and painted as well as the new swing arm mounts in the cart. I'm ready too install the swing arm back in the cart and get the brake cables back in as well. I also got the forward/reverse linkage for the differential can can start building the shifter and push/pull cable to get my reverse back. I'll take and post some pictures tomorrow as I begin putting the cart back together.

11-18-2014, 06:45 PM	#8
smokindawg Gone Wild Join Date: Sep 2012 Location: Missouri Posts: 2,755	Re: The G1. Again! I have the swing arm painted and installed back in the cart. I'm working on a shifter now. It will be made from the shifter made for a boat motor. I just separated the double and will use only one to shift the rear from forward to reverse using the push/pull cable. It should work very well once I figure out the brackets I need to have to hook it all up. Pictures of the swing arm painted and installed. I'll be posting more pictures as I start hooking up and installing the shifter.

11-18-2014, 06:55 PM	#9
meangreenmachine72 Gone Wild Join Date: Apr 2011 Location: New Jersey Posts: 999	Re: The G1. Again! It's going to be well worth it when you are done. Enjoy seeing the pictures. I have 2 bad shape G1's and a 1984. My son and I enjoy working on them, our Cc Ds was stock and we just finished that one. I am going to pm you if you don't mind. I have a question for you. Going down to 20 tonight no garga tonight.

11-19-2014, 11:36 PM	#10
smokindawg Gone Wild Join Date: Sep 2012 Location: Missouri Posts: 2,755	Re: The G1. Again! I was at it again today. I made a mount and fit the linkage on the boat control cable on the rear and mounted the shifter. It looks pretty good but I may have to do a little bit of changing to make it work like I want. It does shift the rear like it should but being used it needs some tweaking. I do want to dress it up some too. Such is the nature of being a cheap azz and build using the materials at hand and don't spend much. I may not make the cleanest looking machine, but can do so on a pretty cheap budget most the time.