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Old 05-07-2013, 08:12 PM   #21
G1-G9
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Default Re: G9A overhaul project

420cc is what i have.
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Old 05-07-2013, 09:14 PM   #22
Tonka329
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Default Re: G9A overhaul project

What hp is the 420cc?
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Old 05-07-2013, 09:26 PM   #23
G1-G9
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Default Re: G9A overhaul project

14/15
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Old 05-07-2013, 09:30 PM   #24
Tonka329
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Default Re: G9A overhaul project

Excellent!
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Old 01-14-2014, 05:40 PM   #25
johnray13
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Default Re: G9A overhaul project

Where does the time go? Shortly after my earlier post last spring, I finished up setting the valve clearance one evening and decided to call it a night. I let my dogs out and a minute later walked past the G9 on my way to bed and noticed smoke under the canopy.

I threw the seat back and saw a lot of melting wiring. I quickly disconnected the battery and counted my blessing that I just caught a potential disaster in time.

Long story short, the previous owner had made several wiring mods, and replaced a bunch of ignition parts, wrapped the fuse in aluminum foil and used lawn mower parts for the ignition (starter relay, VR, key switch, etc)

I ended up having to replace every ignition part except the pickup coil as well replace the entire wiring harness. This was a huge PITA.

I got frustrated and demoralized and didn't keep up with the updates like I had planned.

After I got the ignition/electrical problems fixed I was happy with the way it ran and decided to get the rest of the cart fixed up.

Here are a few pics of some of the body work.
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Old 01-14-2014, 05:42 PM   #26
johnray13
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Default Re: G9A overhaul project

A few more:
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Old 01-14-2014, 06:15 PM   #27
johnray13
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Default Re: G9A overhaul project

I found a company selling new vacuumed molded seats (not covers) and bought new tires/rims and the led light bar on ebay. I already had the winch laying around and bought the diamond plate from a metal shop that sells scrap pieces/remnants for $10. I had to cut it to size on my table saw as well as drill and counter sink the holes for ss screws.

I soda blasted the paint from the canopy tubing and polished the aluminum to 1500 grit and Mothers aluminum polish. The brush guard is 1" EMT I bent and welded together.

I sanded the canopy with 80 grit so it was nice and hairy and put two coats of Herculiner truck bed coating I picked up at Lowes for $60.

I also bought the seat handles (OEM) which it didn't have.

And of course I got it painted. The body had a lot of dings/cracks or other defects that required quite of bit of body putty and sanding. I painted it with Metallic black and silver with three clear coats. I blacked out the dash cubby and under side of the front cowl with flat black.

My mom and my boys love it.
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Old 01-14-2014, 07:24 PM   #28
smallblock450sl
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Default Re: G9A overhaul project

Nice Job! That G9 turned out "sweet", you should be proud
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Old 01-14-2014, 07:42 PM   #29
Mike Mac
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Default Re: G9A overhaul project

Very nice job John!! Like the front bar!! Enjoy!!
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Old 01-14-2014, 08:23 PM   #30
CAMPERCART2013
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Default Re: G9A overhaul project

Nice ride! Did you get light bar new or used on ebay? Also how do you like it?
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