Golf Cart Gas Conversion

Brief overview of my 2005 Club Car DS conversion to gas. This cart was left to die in a farm field for a couple of years. I installed a new Predator 420 engine, F-N-R Go Kart transmission, and Series 40 Torque Converter. Top speed is 21 MPH. There was a fair amount of grinding, cutting and welding involved. This was a fun project, and I think a new paint job is in order.

[walterschilling]

Hello, got side tracked since last post, I fliped the rear, that went very well. I chose a 14hp subaru engine set up with a chain clutch, and did not like that ...but due to other projects, I had to put that aside.Now I am back at it and decided to go all in. I am starting today to rework the frame to adapt to the engine, the 40 series torque converter, and rearrange the placement of my trans.. I find That this is the way to go with great info as a guide, Thanks again for detailed video.

[joeanderson]

this is the most concise, professional, and detailed video. MAJOR thank you. Building one that will essentially be identical.
thank you for including parts, gears, etc. i am wanting to add a live axle to my cart to get more speed. the original rear end in my cart is 12.5:1 ratio so speed is not going to come from the standard axle you have on your cart.

[sharptoothtrex]

This is a great idea you did, lad. You did such a great job making this a great Learner's Permit starter car.

[jamiepatrone]

Nice I’ve watched every electric to gas conversion video there is and yours seems to be the best. I’m building my 2003 club car like yours. Nice work.

[walterschilling]

Just finished a 1998 basket case, especially everything was in crates, now I am on this conversion, installing a Subaru ex40, they have the exhaust on the top and that created a problem with the body, had to position the elbow to the side , other than that your blueprint is on the money

[Mirageman]

Very similar to the conversion I did on my 94 EZGO. Wish I would have gone with the larger engine like you did though. But I've since sold mine so I might build another one day.

[tearoffabite]

I did a similar build i did use a gas rear end on electric frame. Electric frame is way stronger than gas and also did the brake flip and turned the axle like you with 6-1 gears and a comet clutch no chain dose 40 mph I like how you think.

[walterschilling]

Hello BIGBLOK, sucess, I had the Shaft turned down to 7/8 s to accept the 10 tooth drive gear . That has made a great difference, I would say 18 to 20 on the cart and would compare it to my other clubcar gas but with a little more power 14hp subaru engine. I am still fiddling with the vibration rattling problem while at a standstill . I have a original clubcar tray motor mount that I may retrofit so the front of the mount with the rubber motor mount floats on the top of the frame. I think this will surely resolve the problem .. Must say, like always, Your video and expertise has been a great help to tweeking this project ... When I started this a few years ago, there was a point that, I just had enough and was gonna set it on fire, but then I saw Your video. LOL I will do a video when it gets warmer in Pennsylviania.\

[GAG]

Would be nice to see all the details on this build. You said to stay tuned for the full build, it been 3 years and we are still waiting!

[walterschilling]

Hello My Friend, wanter to give you an update on the conversion, well, it all comes back to the engine I choose, which is a great engine ...BUT... the exhaust exits is at the top of the engine, I Had to modify that whole section above heat shield and air space to clear for the seat closeure. and fabricate the manifold outake tube as well. I had the yellow spring on the driven clutch it was a lot of torrque just about lifted the front off the ground, but I did not like that , so I went back to the red spring and and drilled another hole inbetween 2 &3 for spring tension .The rotation is the same and proper direction. Now for the Biggie, I had the shaft turned down to & 7/8 ths to accept the 10 tooth gear with the 3/16ths keyway. I orginally was at a 14 tooth and a 40 chain . . I keep refering to your build and it helps me to stay focused . Thanks

[tjstrain]

You are the only one that has the engine mounted rigid to the main frame with a chain tension, the others mount the engines on a swing arm mounted plate not needing a chain tensioner. I Have a 94 stock gas cart FE290 in it. Debating to just swap engines. I also have a 93 electric FLOOD cart, along with a fiberglass jeep body. I might just start from scratch and modify this frame to except the gas Pred. 420 motor that i also have. Pro’s and cons to the two different ways to mount the motor and trans??? Great video by the way.

[walterschilling]

Hello my Friend, thanks for all the tech advice, I was hoping that you received the link to my driven clutch directly to the gear box stepping the 5/8 shaft and a extender shaft coupled. I do have that in one of my videos. I installed a 14hp subaru 40ex engine with the gearbox. The problem with this type engine is that the exhaust exits from the top of the engine so my clearence from the seat was very limited. I did compensate for the heat exchange . I found a OEM gas clubcar pan mount that I will install this spring which will lower the engine from my temporary fix. I may remount the gearbox, to bring it closer to the rear, was wondering if the shorter chain distance would make any difference in the drive... I got another shaft and stripped the windings, (2nd one I did, no fun at all } and I will turn three quarters of the shaftthat down to 7/8ths to acomadate the 10 tooth 40chain gear.My clutch is mounted same as yours, I did install the green/yellow reverse spring, but I noticed that yours was still the factory red spring . I maybe should have left well enough alone? Cheers

[racerxtex]

Great job!! Now I see how you did some stuff.

[garynitzskysimplyclean]

Great build and video! I just finished my club car ds and used some of your ideas like turning the axle 180°, which made way more sense. I used the predator 420 with the 40 series, but was able to order one with a 5/8" shaft so driven clutch went right on the reverse gear box and then used the 10 tooth 40 series sprocket to go to the the electric motor spindle that I pressed out similar to yours but I was only able to find a 13 tooth sprocket for it. My question to you or anyone on the thread how can I get better top speed? I can only get 10-14 mph tops. Would the sprocket on the pressed out motor shaft need to go larger or smaller? I know I can possibly replace the gears in the axle assembly, but the cost is over $500. I do have the stock 18" tires and it's not lifted, would lifting and putting 23" tired make that much of a top end difference? Thanks everyone, I hope to post mine when I get all the little kinks worked out.

[tarzanmukai]

Fantastic job! Thank you for the video. What type of accelerator cable did you use, ( Z bend end, etc..) and do you have more pics of your bracket so I can copy the shape and configure it next to the gas pedal. This is what I am stuck with, any help is Greatly appreciated thank you.

[stnelsen]

Reading posts said you are still driving the cart. About to put same forward reverse gearbox on a 420cc predator. Unless you replaced must still be working good????

[walterschilling]

Finally got the engine and trans fitted, I mounted the pulley to the gear box, I tried using a push choke cable but I can't get full throttle, I think I will use your method, do you have any info on the cable you used, I have the same cart. Thanks!

[douglasstaats]

This is the first video I've seen where they flipped the rear end

[walterschilling]

still at it, Im replacing the subaru engine with the13hp predator.mainly becasue the drive shaft steps up so the clutch cannot slide all the way onto the shaft
.and the exhaust exits from the question is this is there a vaccum nipple on the engine to drive the fuel pump?

[jlistdiy]

You had any issues with the chain coming off the rear axle when hitting large bumps