1994 Ezgo Textron Freedom gas conversion project

monacayankee · 07-03-2018, 07:55 PM

Free 1994 Ezgo electric cart. I am swapping a gx200 motor in.

Cut out most of the rusted battery tray

Threw away junk top

Tore out all of the electronics

Cut off brack cable holder plate to have my dad make a new one to be rewelded to new metal.

Had my dad press out the electric motor shaft at work. Took 800psi and the motor popped apart leaving the shaft with pieces of the motor laying around it.

Having my dads friend key the motor shaft for the sprocket

$75 6.5hp gx200 off a pressure washer. governor is getting removed

$50 Comet 30 torque converter - Kevlar belt

1 1/8 bore 14 tooth keyed sprocket to go on shaft

Pics to be added as project is ongoing.

LukeL · 07-03-2018, 08:42 PM

Sounds fun [emoji1303]

Club Car DS driver’s club #59

monacayankee · 07-04-2018, 04:01 PM

Free 1994 Ezgo electric cart. I am swapping a gx200 motor in.

Cut out most of the rusted battery tray

Threw away junk top

Tore out all of the electronics

Cut off brake cable holder plate to have my dad make a new one to be rewelded to new metal.

Had my dad press out the electric motor shaft at work. Took 800psi and the motor popped apart leaving the shaft with pieces of the motor laying around it.

Having my dads friend key the motor shaft for the sprocket

$75 6.5hp gx200 off a pressure washer. governor is getting removed

$50 Comet 30 torque converter - Kevlar belt

1 1/8 bore 14 tooth keyed sprocket to go on shaft

Pics to be added as project is ongoing.

Working on making fixing rust today.

dundeebarnbuggy · 07-04-2018, 05:02 PM

I admire your enthusiasm! Some other points to consider:

You might have to back up sometime. How are you going to get reverse?

A keyed sprocket on a splined shaft will be a #$%^& to keep tight, short of welding it permanently.

Now, you need to plan an engine mounting/cradle that clamps to the axle and supported in the front allowing it to move with the axle over bumps.

Keep us posted on your plans!!!

monacayankee · 07-04-2018, 07:17 PM

Quote:

Originally Posted by dundeebarnbuggy

I admire your enthusiasm! Some other points to consider:

You might have to back up sometime. How are you going to get reverse?

A keyed sprocket on a splined shaft will be a #$%^& to keep tight, short of welding it permanently.

Now, you need to plan an engine mounting/cradle that clamps to the axle and supported in the front allowing it to move with the axle over bumps.

Keep us posted on your plans!!!

I might add a go kart transmission in the future. For now forward is good.

I'm having the shaft out of the electric motor keyed and the sprocket is keyed. I will put a key between and use the set screws and maybe throw a tack down on the key. The electric engine case will be cut for the chain to run through it to the sprocket.

Engine is not going to move with the axle. I will be using a chain tensioner. The engine will be mounted on an adjustable plate off eBay.

dundeebarnbuggy · 07-04-2018, 08:15 PM

Pushing it backwards is going to get old fast! It is not like a motorcycle where you can just put your feet down. But hey! If you have the will,,,

more power to ya! Mount the motor in a cradle. Chain tensioners ONLY work properly when between 2 FIXED shafts with the chain loaded in ONE direction only. Leaf springs do NOT keep the rear axle at a set distance from your jackshaft when accelerating and braking. Add the rapid up and down axle movement of bumps and engine braking loading the opposite side of the chain during decelleration and you have got a chain looking for another place to go.

monacayankee · 07-04-2018, 10:11 PM

Quote:

Originally Posted by dundeebarnbuggy

Pushing it backwards is going to get old fast! It is not like a motorcycle where you can just put your feet down. But hey! If you have the will,,,

more power to ya! Mount the motor in a cradle. Chain tensioners ONLY work properly when between 2 FIXED shafts with the chain loaded in ONE direction only. Leaf springs do NOT keep the rear axle at a set distance from your jackshaft when accelerating and braking. Add the rapid up and down axle movement of bumps and engine braking loading the opposite side of the chain during decelleration and you have got a chain looking for another place to go.

I'll weld rebar in to hold the suspension solid before I make a cradle off the axle. I'm going to run a chain guide and a tensioner or two.

monacayankee · 07-05-2018, 07:35 PM

Welded in new brake cable bracket. Welded in crossbar. Going to work on the other side of the engine cradle Friday and through the weekend. Lots of parts coming Monday.

monacayankee · 07-09-2018, 06:43 PM

Engine cradle tac welded in.

LukeL · 07-09-2018, 08:37 PM

Looking good. The electronics from that cart will be put to use[emoji1303]

Club Car DS driver’s club #59

07-03-2018, 07:55 PM	#1
monacayankee Not Yet Wild Join Date: Jul 2017 Posts: 37	1994 Ezgo Textron Freedom gas conversion project Free 1994 Ezgo electric cart. I am swapping a gx200 motor in. Cut out most of the rusted battery tray Threw away junk top Tore out all of the electronics Cut off brack cable holder plate to have my dad make a new one to be rewelded to new metal. Had my dad press out the electric motor shaft at work. Took 800psi and the motor popped apart leaving the shaft with pieces of the motor laying around it. Having my dads friend key the motor shaft for the sprocket $75 6.5hp gx200 off a pressure washer. governor is getting removed $50 Comet 30 torque converter - Kevlar belt 1 1/8 bore 14 tooth keyed sprocket to go on shaft Pics to be added as project is ongoing.
monacayankee Not Yet Wild Join Date: Jul 2017 Posts: 37

07-03-2018, 08:42 PM	#2
LukeL Gone Wild Join Date: Jun 2017 Location: Savannah, GA Posts: 6,539	Re: 1994 Ezgo Textron Freedom gas conversion project Sounds fun [emoji1303] Club Car DS driver’s club #59

07-04-2018, 04:01 PM	#3
monacayankee Not Yet Wild Join Date: Jul 2017 Posts: 37	Re: 1994 Ezgo Textron Freedom gas conversion project Free 1994 Ezgo electric cart. I am swapping a gx200 motor in. Cut out most of the rusted battery tray Threw away junk top Tore out all of the electronics Cut off brake cable holder plate to have my dad make a new one to be rewelded to new metal. Had my dad press out the electric motor shaft at work. Took 800psi and the motor popped apart leaving the shaft with pieces of the motor laying around it. Having my dads friend key the motor shaft for the sprocket $75 6.5hp gx200 off a pressure washer. governor is getting removed $50 Comet 30 torque converter - Kevlar belt 1 1/8 bore 14 tooth keyed sprocket to go on shaft Pics to be added as project is ongoing. Working on making fixing rust today.
monacayankee Not Yet Wild Join Date: Jul 2017 Posts: 37

07-04-2018, 05:02 PM	#4
dundeebarnbuggy Gone Wild Join Date: Oct 2016 Location: Dundee quebec Posts: 3,190	Re: 1994 Ezgo Textron Freedom gas conversion project I admire your enthusiasm! Some other points to consider: You might have to back up sometime. How are you going to get reverse? A keyed sprocket on a splined shaft will be a #$%^& to keep tight, short of welding it permanently. Now, you need to plan an engine mounting/cradle that clamps to the axle and supported in the front allowing it to move with the axle over bumps. Keep us posted on your plans!!!

07-04-2018, 08:15 PM	#6
dundeebarnbuggy Gone Wild Join Date: Oct 2016 Location: Dundee quebec Posts: 3,190	Re: 1994 Ezgo Textron Freedom gas conversion project Pushing it backwards is going to get old fast! It is not like a motorcycle where you can just put your feet down. But hey! If you have the will,,, more power to ya! Mount the motor in a cradle. Chain tensioners ONLY work properly when between 2 FIXED shafts with the chain loaded in ONE direction only. Leaf springs do NOT keep the rear axle at a set distance from your jackshaft when accelerating and braking. Add the rapid up and down axle movement of bumps and engine braking loading the opposite side of the chain during decelleration and you have got a chain looking for another place to go.

Today
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07-05-2018, 07:35 PM	#8
monacayankee Not Yet Wild Join Date: Jul 2017 Posts: 37	Re: 1994 Ezgo Textron Freedom gas conversion project Welded in new brake cable bracket. Welded in crossbar. Going to work on the other side of the engine cradle Friday and through the weekend. Lots of parts coming Monday.
monacayankee Not Yet Wild Join Date: Jul 2017 Posts: 37

07-09-2018, 06:43 PM	#9
monacayankee Not Yet Wild Join Date: Jul 2017 Posts: 37	Re: 1994 Ezgo Textron Freedom gas conversion project Engine cradle tac welded in.
monacayankee Not Yet Wild Join Date: Jul 2017 Posts: 37

07-09-2018, 08:37 PM	#10
LukeL Gone Wild Join Date: Jun 2017 Location: Savannah, GA Posts: 6,539	Re: 1994 Ezgo Textron Freedom gas conversion project Looking good. The electronics from that cart will be put to use[emoji1303] Club Car DS driver’s club #59

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