My G2 Rebuild Project

[jacot23]

Originally Posted by marks141

Been a couple days, any progress with the build?


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I'm still tearing down

Undecided for sure whether I'm going to cut out the bent cross member and replace it. I think I remember owner #2 driving off into a pond late one Friday night and this is the aftermath:







I do have 3 boxes arriving from NY today and tomorrow with some body parts

With work and kids this is going to be a long process.

[marks141]

This is my setup up for my cart.

I went with a bigger engine and a 7" lift with 25" tires so I dropped and pulled it back to level everything and to get the room for my rear tires.
If you do replace it, try and grind or cut the ears off that so you can re use them, might be able to weld them back onto what ever you plan to use to replace it. If you don't buy anything bigger than 20" tires you can put the arm in the same spot. If you decide to move it back you will end up needing longer break cables and other smaller things.

[jacot23]

Originally Posted by marks141

This is my setup up for my cart.

I went with a bigger engine and a 7" lift with 25" tires so I dropped and pulled it back to level everything and to get the room for my rear tires.
If you do replace it, try and grind or cut the ears off that so you can re use them, might be able to weld them back onto what ever you plan to use to replace it. If you don't buy anything bigger than 20" tires you can put the arm in the same spot. If you decide to move it back you will end up needing longer break cables and other smaller things.

Thanks for the picture, between this and TheNewGuy's frame thread I've got a decent idea if I do replace that crossmember; which is very likely, as I'd rather do it now while the cart is mostly disassembled.

Seat backs arrived today

[smallblock450sl]

I must say, I've never seen that frame member bent. It would put the swing arm in a bind. I think Marks, upgraded frame member looks good, but I would not have welded just the sides. Top/bottom/sides and even the hole in the bracket. Wish Ron/Thenewguy would sell his drop frame, it's outstanding work

[jacot23]

Originally Posted by smallblock450sl

I must say, I've never seen that frame member bent. It would put the swing arm in a bind. I think Marks, upgraded frame member looks good, but I would not have welded just the sides. Top/bottom/sides and even the hole in the bracket. Wish Ron/Thenewguy would sell his drop frame, it's outstanding work

I bet he'd sell several.

I remember laughing my butt off the night that happened. We were sitting around outside the clubhouse waiting for the last group to come in and turn in scores (Friday scramble). The owner at the time was slightly intoxicated (ok, really drunk and should not have been driving anything) and drove into the pond on number 9. The passenger jumped and the driver was thrown over the front of the cart into the pond; cart must have hung an old stump. After we figured out he was alright we all laughed our butt off! I bought the cart a few years later and it drove good enough that I didn't notice or really even look at that part of the frame.

By your post about binding the swing arm I could only assume that you're suggesting replacement?

[TheNewGuy]

Originally Posted by smallblock450sl

I must say, I've never seen that frame member bent. It would put the swing arm in a bind. I think Marks, upgraded frame member looks good, but I would not have welded just the sides. Top/bottom/sides and even the hole in the bracket. Wish Ron/Thenewguy would sell his drop frame, it's outstanding work

Thanks for the kind words Dave, I just don't want to deal with the liability issue.

>>> http://www.buggiesgonewild.com/desig...me-repair.html

[ironmonkey17]

I had that same bent part of the frame on my G2 frame, I cut that section out and re-welded a new pipe in..

[jacot23]

Well I decided to turn the frame over for a closer look and discovered that I HAVE to replace the cross member :(
The frame itself looks decent, at least no cracks I can see yet.

[GaryMAc]

My G2 is an 89 but was in pretty bad shape, so I just sanded the body filled in the ripples with flexible bondo, primed and painted , recovered the seats myself, put lift kit, new starter, new breaks and drums, new fuel pump, new tires and wheels, added a rear seat and surfboard top and it looke pretty darn good. Just a little TLC does wonders for these old carts. ANd right now I am rebuilding the clutch with the help and advice from some of the people in this forum who are very knowledgeable and willing to help.

ANd to go along with the scheme for the surf boards and you have to look close but the flames down the sides are actually schools of fish

[jacot23]

Originally Posted by GaryMAc

My G2 is an 89 but was in pretty bad shape, so I just sanded the body filled in the ripples with flexible bondo, primed and painted , recovered the seats myself, put lift kit, new starter, new breaks and drums, new fuel pump, new tires and wheels, added a rear seat and surfboard top and it looke pretty darn good. Just a little TLC does wonders for these old carts. ANd right now I am rebuilding the clutch with the help and advice from some of the people in this forum who are very knowledgeable and willing to help.

That does look pretty darn good!