G19E Limo Frame rusted out

[kenhouser]

OK gentlemen(golf cart guru's) i have a pretty major task in front of me and any ideas or help would be most appreciated.
More pics to come.
I have a stretched 1999 G19e and you can poke your fingers thought the frame. and the battery box just fell off.

I have a 1996 g16e regular frame that is in pretty good shape.
so the task is to cut the both frames off somewhere and put front of the stretched cart and the rear of the non stretched cart together.
Easy right?
The frames look the same all except the cradle that rear axle and motor swing on. so if anybody has done anything like this. any ideas or WHAT NOT TO DO would be great.
I assume this will be close to the same work as stretching one. so if anyone can point me at some g19e yamaha stretch threads those might help also.

[CP241]

That seems to be a pretty common place for the Yamaha's to rust out. My G9 is gas, but was rusted out in the same spot.

Rather than try and graft 2 carts together into 1 (which sounds like a nightmare if you ask me? why not just get some tubing (use heavier wall tubing than OEM... the OEM is quite thin) and repair the frame? Seems much more reasonable to find where the metal is good, cut it back to where the metal is solid (one section at a time) and weld in the new tube.

Or cut the pieces you need out of the frame (if that is just a parts cart/frame) and use that, you wouldn't have to mess with trying to bend any of the tubing.


just my .02

[kenhouser]

thought about the bending of the pipe.
the g16e frame is already bent.
and yea i can cut the piece needed for each side and weld in
but seems like 2 connection points would be easier than 4 connection to fab up
the problem with cutting to pieces and welding in is all the other welds that would have to happen three side brace on each side the seat support/controller mount stuff not count the cutting the battery box off the doner frame so i can get two separate pieces.

lot of work either way i guess

thanks for the input

ken

[CP241]

If it were me, and the rest of the frame minutes those to parts is good, I'd just repair the frame and fab my own buttery box. Either way you've got a decent bit if work in front if you, but it would be easier than combining 2 frames to make 1. And more robust long term because you can choose your own steel, and add structural supports if needed.

[smallblock450sl]

When "stretching a Yamaha", you cut the main frame tubes under the floor board area and extend it with smaller or larger steel tube and weld the splices togeather. As you have found a good donor frame, I would take up the sheet metal flooring, find the rear splice joint weld, cut it off and install the rear section from the donor frame in it's place. One cut, one weld and be done with it. Good luck on your project

[kenhouser]

that is my plan at the moment. i hope to start this weekend
thanks for all the replies and well wishes i may need them

[BBBHC]

If nothing else, you'll learn something! Hope you post your progress on this build, I'd like to follow along!

[kenhouser]

ok guys i was reading BGW last night like every night and i ran across this thread. Budule is my new hero and this thread http://www.buggiesgonewild.com/elect...cart-half.html

so here i am scared to start on my project, so i drank a couple (of 12 packs ) and cut two golf carts in half. ( no I am not the mad man Budule is)
i cut the donor frame and the limo frame in half and now it don't seem impossible any more so here is a couple of pics

[kenhouser]

so i think that if i put this

[kenhouser]

into this after it is cut