Yerf Dog 3203 light refurbishing

Gasteffens

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Wish I had had time to mount it but this will be sweet. Then will be to take my time running wires, there’s only a few but I like to make my wiring tight - I used to help fellow volunteer firefighters setup emergency lights in their vehicles.
 

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Gasteffens

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Slow going due to schedule but I was impressed how the outlet box fit that corner there. Two conduit clamps and it is very secure. Can’t wait to start connecting the wires in there, I got one wire off the engine mostly run except for some fine tuning of how it sits. Then dad duty called so that was all for today.
 

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Gasteffens

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Edit:

Pictures added showing where wires will go and a few uses I will have for that angle steel there. Also note a relay mounted near the starter which will be my kill circuit, and that old kill switch will get relocated somewhere near the engine.


Only picture I could grab before the phone went dead and I had to go back in the house lol.

Getting more done on the wiring to my key box up front, and starting to decide on how to place things out back. Going to use a relay for my kill mounted at the engine and opened with an ignition feed. Also will add an auxiliary kill switch somewhere near the engine, probably will reuse the stock one in a new location.

Wiring is pain in the sense of getting it all where you want it and make it look half way decent. I’m not that great at it, but do appreciate nice clean wiring. Stay tuned, we’ll see how this goes, I’ll add more pics when I get back out there.
 

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Gasteffens

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Edit:

One more picture added.

Nice to have the front mostly buttoned up. I color coded all the wires so where they go back by the engine will be easy, it’s just a matter of routing them in a half hearted decent way that takes the most time.
 

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Last edited:

Gasteffens

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Re-did the wiring layout at the engine and connected a few more wires at the battery box including the relay for what will be the lights. The large loops of red and black in the box are what I stubbed in to connect to the battery; I’ll need it in there to make the final connectors - the cardboard box is a place holder until I’m ready to try starting it, I don’t want to leave the battery to sit in a non insulated shop now that it’s getting colder and especially overnight. I am very close to a test start with the engine in the frame though!
 

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Gasteffens

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Rough in of where the secondary kill switch will go, and very early renditions of where the rear running lights will reside. Brackets need trimming to closer follow the frame contour and the edges rounded/smoothed out, but I think they will serve this rig well.
 

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Gasteffens

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Pretty happy with the engine wiring, just need to do the lights but that won’t be a big deal.

Forgive the terrible quality video but I wanted to hear it run in frame. If we get a nice day I’ll drop the battery in there and do a gentle test run around the yard before I turn it around and dissect the front end a little bit.

 

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Gasteffens

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Had to connect the battery and see if everything worked, which it did. Relay for lights activates so just need to tap in there when I get them off the other machine. Flipped it around to start on the front end work.
 

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Gasteffens

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Moving the needle a bit, got some done on the front end and found a place I will be adding another bushing. Got my donor fog lights started and am working on the seat belts. Also stated in on my makeshift windscreen with a half size piece of free plexiglass. If we get a nice day I’ll try another video, I did a midnight 20 degree test drive in the yard with no lights and it ran awesome but couldn’t see anything to film, and after 5 minutes decided to quit while I was ahead, ha!
 

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Gasteffens

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10 picture limit per post evidently!

See the last picture there, PM me if you can use those old parts for donor metal or just practice metal and I’d like to get them to someone for $FREE.99 if you are in the Morris, IL area before I throw them to scrap. First come first serve.
 

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Gasteffens

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Looking good!

I'd keep those bits around, if you have anywhere to stash them - never know when they'd come in handy

Sure, I’ll keep them around but if someone else really needs them they are there. With life schedules even this project was probably more than I can chew, and likely won’t get back into these for some time. In the land of perfect I would have had a better shop, more tools in one place, and more time to do things better and cleaner.
 

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Took care of the last major point of slop in the steering, only to discover the bolts which hole the steering wheel on will need to be snugged down too, ha!

And a second test with the “windshield”. I think clean up the bolts and call it till spring when I can paint that cross beam there.
 

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Budget GoKart

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Man i wish i could buy a new rear swing arm my 3202's swing arm is worn out baaad but then again ive got a big block on it so i prob should make the right setup. Also any big block motor on the yerfdog karts peps em right up and man they will climb any hill drive any terrain and go plety fast the big blocks are awesome
 

Gasteffens

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Man i wish i could buy a new rear swing arm my 3202's swing arm is worn out baaad but then again ive got a big block on it so i prob should make the right setup. Also any big block motor on the yerfdog karts peps em right up and man they will climb any hill drive any terrain and go plety fast the big blocks are awesome
You know, I was just thinking, since BMI makes those swing arms to order, you could always call and see if they could do one special for you with a different engine plate or minus the plate and put your own in. Worth asking I suppose!

I’d considered a larger engine but went this way because it will be a family yard and light trail kart and I’m going for smoothish, reliable and simple. If it was just for me, I’d see if I could pillage one of the many Honda GX big blocks laying around at work 😁
 

Budget GoKart

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Them honda big blocks are fast! Mines a 340 but has a 390 carb which means its a 390 so it made 12-13hp then i removed the goveneor and its sketchy fast it goes 50-60mph which is fun but i needed a charging stystem so im gonna buy a duromax 440 and plop the 18hp of fury on there and have an absolute blast on it
 

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Got the lights hooked up. Next will be to go around and check torque on all bolts and tidy up what I can with longer or shorter bolts. I plan to throw a little touch up paint at a few spots and put down some black stick on padding for the floor pans, but not till it’s warmer outside.


 

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Gasteffens

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Well it’s done till the spring when it’s warmer to put on some touch up paint and stick on items. Couldn’t help myself and I took it for a spin, no battery I just bypassed the circuit. Engine has plenty of torque stock and I couldn’t record it but hit 30mph with the phone gps. That’s enough for it’s intended use, ha. Before I take any kiddos out I’ll give it one more once over for tight bolts. Also got the hours up enough I can change the oil next shop day.

 

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