Trail Rider's Cushman Limousine

Trail Rider · 05-19-2007, 05:45 PM

I am going to attempt to start this thread and post pictures as I go for any of you who want to follow the rebuilding of my 2002 Cushman Bellhop 6 passenger cart. Please bear with me as I am trying to learn how to use my new camera. Here is a picture of the cart. The rear seats and two rear body sections have been removed as well as the roof. The seats and roof have been stored for later use. The body sections are in the shop getting their makeover.

The engine is a Robin 352cc 2 cylinder and runs great. At the time of the photo all I had done was to use a pressure washer on it. It's all in great shape. I will change the plugs and the oil. Does any one know if these use an oil filter? If so I haven't found it yet.

The existing tires on this thing are 5.70x8. They look like they belong on a kid's wagon and they are 5 lug. Besides that as soon as you left the pavement you were stuck with these things. I may also have to remove a leaf or two from the springs to soften the ride and allow some articulation. This chassis is STIFF!
Thanks to Rizzo20 for finding a site that sells 5 lug golf cart wheels I was able to order a set. I will be using off-road 20x7-8 tires and standard steel wheels. I know lifting this thing and putting on a set of 25's would be cool, but I plan to use this on hilly roads in a campground and I didn't want to make 5 passengers jump off every time I came to a hill.

Here are a few pics of the two rear body sections. I currently have them in the shop working on them in my "spare" time

The black spots are where there were small holes punched or drilled that didn't need to be there. There are also several scratches and gouges that will require filling. I plan to paint it silver when ready.

That's about all for this round. More pics coming soon!

NO NO NO E-Z-GO! · 05-19-2007, 05:55 PM

That is a cool little machine! How does it ride with the seats right above the wheels?

The EH-29 and EH-35 Robin engines do use an oil filter. If you don't know how long it's been since it was changed, I'd suggest a new filter and o-ring. They are a permanent washable filter (use brake parts cleaner or carburetor cleaner). It is located sort of behind the drive clutch and is held on by (3) 10mm bolts:

I would be leary of pressure washing around the electrical components. I found that a good engine degreaser with some warm water and a brush gives a stellar job. If you're not into brushing, pick up some of that etching cleaner for aluminum and just don't get it on the body paint. That stuff will amaze you and make that thing gleam like new, if not more.

Any plans for special effects on the silver paint?

As for hauling all those people around, I think those are made to handle a lot of weight. You could, however, put some carburetor jets in it.

GOOD LUCK!

Trail Rider · 05-19-2007, 06:27 PM

It is kind of strange sitting in front of the front wheels. Its like when you turn you go sideways, but you get used to it. As I said before this thing is stiff. If you get on uneven ground sometimes you wont be moving and you look at the rear wheel and it is off of the ground, spinning. I think what will help that is: 1. The current tires basically have no tread and are hard as a rock. In fact they are filled with something to make them solid. The new tires will have aggressive tread and will be softer. 2. When the cart is put back together it will weigh more than it does now, helping the traction issue. 3.If the problem persists at this time I will start one at a time removing leaves from the springs to soften ride. (This thing has leaf springs front and rear). 4. And most desperate: Weld the spider gears up to make a direct posi.

Trail Rider · 05-19-2007, 06:32 PM

Thanks for the info on the oil filter. I would never have found it. As for the special effect on the silver paint, I will probably at the most have some vinyl graphics made up. I just think a "wild" paint job would look out of place on this type of cart.

4x4 CC · 05-20-2007, 12:20 AM

DO they not make 5 lug atv rims?

TheNewGuy · 05-20-2007, 06:06 PM

Nice project. Looks in very good condition. Keep the pics coming!!

Trail Rider · 05-20-2007, 06:25 PM

Quote:

Originally Posted by 4x4 CC

DO they not make 5 lug atv rims?

I'm sure they do but to get one with the same bolt circle and still be small enough diameter is difficult. I checked on ebay and they listed what the wheels fit, but didn't give any measurements. Problem is solved anyway.

Trail Rider · 05-20-2007, 06:26 PM

Quote:

Originally Posted by TheNewGuy

Nice project. Looks in very good condition. Keep the pics coming!!

Thanks and will do.

Xtreme Cartz · 05-20-2007, 06:52 PM

Cool project!

That frame looks a lot like the EZGO's but beefed up and thicker.
Thats a nice shop you have there!

Trail Rider · 05-20-2007, 09:04 PM

Quote:

Originally Posted by Xtreme Cartz

Cool project!

That frame looks a lot like the EZGO's but beefed up and thicker.
Thats a nice shop you have there!

EZ-GO does make a cart exactly like this except for the name plates. Thanks for the compliment about the shop, but it isn't mine. That's actually the shop where I work. I am the painter at a GM dealership. One of the few perks is working on my own stuff!

05-19-2007, 05:45 PM	#1
Trail Rider Gone Wild Join Date: Jan 2007 Location: southern Ohio Posts: 254	Trail Rider's Cushman Limousine I am going to attempt to start this thread and post pictures as I go for any of you who want to follow the rebuilding of my 2002 Cushman Bellhop 6 passenger cart. Please bear with me as I am trying to learn how to use my new camera. Here is a picture of the cart. The rear seats and two rear body sections have been removed as well as the roof. The seats and roof have been stored for later use. The body sections are in the shop getting their makeover. The engine is a Robin 352cc 2 cylinder and runs great. At the time of the photo all I had done was to use a pressure washer on it. It's all in great shape. I will change the plugs and the oil. Does any one know if these use an oil filter? If so I haven't found it yet. The existing tires on this thing are 5.70x8. They look like they belong on a kid's wagon and they are 5 lug. Besides that as soon as you left the pavement you were stuck with these things. I may also have to remove a leaf or two from the springs to soften the ride and allow some articulation. This chassis is STIFF! Thanks to Rizzo20 for finding a site that sells 5 lug golf cart wheels I was able to order a set. I will be using off-road 20x7-8 tires and standard steel wheels. I know lifting this thing and putting on a set of 25's would be cool, but I plan to use this on hilly roads in a campground and I didn't want to make 5 passengers jump off every time I came to a hill. Here are a few pics of the two rear body sections. I currently have them in the shop working on them in my "spare" time The black spots are where there were small holes punched or drilled that didn't need to be there. There are also several scratches and gouges that will require filling. I plan to paint it silver when ready. That's about all for this round. More pics coming soon!

05-20-2007, 06:06 PM	#6
TheNewGuy Admin/Moderator Join Date: Dec 2006 Location: Ohio Posts: 18,044	Nice project. Looks in very good condition. Keep the pics coming!!
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05-19-2007, 05:55 PM	#2
NO NO NO E-Z-GO! Gone Wild Join Date: Dec 2006 Location: ComplainAboutNoNo'sProfile-Ville Posts: 4,995	That is a cool little machine! How does it ride with the seats right above the wheels? The EH-29 and EH-35 Robin engines do use an oil filter. If you don't know how long it's been since it was changed, I'd suggest a new filter and o-ring. They are a permanent washable filter (use brake parts cleaner or carburetor cleaner). It is located sort of behind the drive clutch and is held on by (3) 10mm bolts: I would be leary of pressure washing around the electrical components. I found that a good engine degreaser with some warm water and a brush gives a stellar job. If you're not into brushing, pick up some of that etching cleaner for aluminum and just don't get it on the body paint. That stuff will amaze you and make that thing gleam like new, if not more. Any plans for special effects on the silver paint? As for hauling all those people around, I think those are made to handle a lot of weight. You could, however, put some carburetor jets in it. GOOD LUCK!

05-19-2007, 06:27 PM	#3
Trail Rider Gone Wild Join Date: Jan 2007 Location: southern Ohio Posts: 254	It is kind of strange sitting in front of the front wheels. Its like when you turn you go sideways, but you get used to it. As I said before this thing is stiff. If you get on uneven ground sometimes you wont be moving and you look at the rear wheel and it is off of the ground, spinning. I think what will help that is: 1. The current tires basically have no tread and are hard as a rock. In fact they are filled with something to make them solid. The new tires will have aggressive tread and will be softer. 2. When the cart is put back together it will weigh more than it does now, helping the traction issue. 3.If the problem persists at this time I will start one at a time removing leaves from the springs to soften ride. (This thing has leaf springs front and rear). 4. And most desperate: Weld the spider gears up to make a direct posi.

05-19-2007, 06:32 PM	#4
Trail Rider Gone Wild Join Date: Jan 2007 Location: southern Ohio Posts: 254	Thanks for the info on the oil filter. I would never have found it. As for the special effect on the silver paint, I will probably at the most have some vinyl graphics made up. I just think a "wild" paint job would look out of place on this type of cart.

05-20-2007, 12:20 AM	#5
4x4 CC Frog Hunter Join Date: Dec 2006 Location: Little Rock, Ar Posts: 1,161	DO they not make 5 lug atv rims?

05-20-2007, 06:52 PM	#9
Xtreme Cartz The Fabricator Join Date: Dec 2006 Posts: 2,016	Cool project! That frame looks a lot like the EZGO's but beefed up and thicker. Thats a nice shop you have there!