Rigid GX160 > GX390 Clone Off-Road Resto-Mod

[Sleepy122CID]

I finally got a chance to do a little work on this sucker today. I loosened the sprocket and let it dangle just to see where I may be able to get the engine when the new axle, sprocket, and hub get here. Got the old seat off, and mocked up where the new seat and engine may sit.

Got it inside and on some "jack stands"

Removed the seat

Cut these seat mounting tabs off

Got the new seat brackets cut and ready to weld to the frame. The new seat will sit a couple of inches lower so us big kids might not be sticking out of the cage heh. I am 5'8" or so, and about the shortest person who will ride it, so I'm going to stretch the seat back as far as I can and still be fairly comfortable.

My shoulders were hitting the bar/cage support behind the seat so I cut the bar...

... and angled it back to make some more room. I was even able to move the seat back another inch or so after this!

Tomorrow I hope to get the engine mount modified for the big block, finish welding the bar behind the seat, grind everything I've cut smooth, and weld on the seat brackets. If I'm feeling froggy I just might strip it down to the main frame and prep it for wrinkle black powder coat.

 

[Fast Eddie]

Keep rockin' Sleepy. Looking good!

 

[Sleepy122CID]

Today I had time to make some decent progress. I'm starting to get excited about this thing moving on its own! I had to stop because I found I am going to need a longer jackshaft so I can run the sprocket and chain on the opposite side of the engine.

First, I finished welding the bar behind the seat. The angle is almost even on both sides . I haven't been welding very long, and this is the first project I've ever really fabricated anything on. Also, I moved the middle-of-the-back rest up about 6 inches to make it a head rest .

Another view, and I figured out how far back I could mount the seat before my shoulders started hitting the bar.

Welded on the seat brackets -

Mounted seat for the first time, then started putting the cage back on to figure out where to mount the engine. Note the badass stainless u-bolts . They were just a hair larger than the ones that were already on there, so I had to drill out every hole first . Not a real big deal, but something I hadn't planned on.

Approximately where the engine will sit:

I was starting to plan the header to clear the roll cage, but it looks like I'll be able to keep the stock exhaust after all!

With the engine this far back, the roll cage won't interfere with the header when I decide to fabricate one. This is about where the driven pulley will sit. I will run 3 bearings on the jackshaft. I had to order a longer jackshaft, for I will have to run the sprocket assembly on the other side of the engine.

 

[Sleepy122CID]

Oh yeah, funny story: I was about to jump in the shower, and noticed a serious farmer's tan on my arms. I was trying to figure out how that could have happened (I was inside all day, and it was raining), then I remembered that even if I man up and wear a t-shirt while welding (instead of a jacket or sweatshirt to block the sparks and spatter), the brightness of the arc will still get me!

 

[Sleepy122CID]

Got some new pedals with one of my orders because they were only like $6 each, and the others looked very rusty. I was looking at some more expensive ones, but the pedal pad looked a lot shorter, perhaps wider though. I realized the ones I got are just like the ones I already had, and they are very narrow! I'm still glad I got them though, for with the powers of new and old combined I now have the best of both worlds!

Now if I can just figure out how to get the friggin locking cap off the rod(s) so I can get what is left of the old pedals off and get the new ones on. Does anyone know how to remove them? It is like a little brimmed hat thing that is on the end of the throttle and brake control rods. I'll try and remember to get some pictures of them up later. Otherwise I may just grind off the brim, drill a small hole, and use cotter pins.

 

[Sleepy122CID]

Save me from myself before I cut these clips off! Are they supposed to be replaceable?

 

[Sleepy122CID]

Last thing for the day... possibly the last update for a week or so. Welded 2 of the 3 jackshaft mounts. I'll have to make the support for the other one before I decide if I will use the same "design" for that mount.

 

[Sleepy122CID]

This weekend was pretty exciting...

Pretty rusty on the underside, but it appears I won't have to replace it yet.

Want to install front fenders, but not enough room between tire and frame -

Look at all that room!

Used some fenders, scrap metal straps, and the old pedal arms -

 

[Jasoninsane123]

very nice dude whatever you do i will be doing snice my kart is on hold


P.S im drunk don't mind my spelling lol dang partys

 

[Fast Eddie]

Great job yet again Sleepy! Looks like you're having fun. BTW, you're doing a great job keeping us updated with lots of good pics and descriptions. Keep it up!

 

[Sleepy122CID]

Thanks. I am having fun. I am starting to realize how amazing it is to have a welder. My mind is starting to operate differently without the limitations of nuts and bolts. I have one more jackshaft bearing hanger to weld up, then when the shaft gets here I'll figure a mount for the last bearing hanger. After I drill cotter pin holes in the brake and throttle rods I should be about done. I'm a little upset, for I realized the powder coating oven I just built may not be tall enough to fit the frame =/. I may be able to angle it in there - we'll see.

Anyone know where to get one piece 6" x 4.5" wheels for tubeless tires?

 

[Sleepy122CID]

 

[fowler]

if u remove the cover on the muffler dont remove back as otherwize the heat gets to the caberetor and boils the fuel in the line and the engine stalls (i just spent today replaceing the whole exust assembally on a gx390 cause it had rusted out causing this issue)
other idea is doing staight pipe and fiting the muffler somewhere else on the pipe
(if it is nessercery to have a muffler)

 

[Sleepy122CID]

Had a chance to do a little tonight after I got home from work and found the longer replacement jackshaft on the porch . Nothing bolted down yet, just propped up to get the measurement for the belt.

This is the best weld I've made so far. I was slightly shocked when I lifted my hood to see that. Don't ask me to make something half this consistent on tubing .

 

[bajagokart]

Why not use some 3/4" pillow block bearings instead of the ones that came with the jackshaft?

 

[Sleepy122CID]

What would the benefit be? I am not familiar with those style bearings...

 

[Sleepy122CID]

Nevermind, I see that would have been much easier to set up, but will these not work well enough?

 

[Fast Eddie]

What would the benefit be? I am not familiar with those style bearings...

Yours will work great. Your setup in my opinion will look better. Pillow blocks are bulky, industrial bearings used in conveyor belt systems.

 

[bajagokart]

Nothing wrong with those bearing I personally like pillow blocks and they are super easy to set up!

 

[Dvill26]

Looks great! Can't wait to see it in action!