club car carryall 2 – twin work cart build *part 2*

Here is the continuation of are cool twin work cart build. In this post we are going to continue with the custom roll cage and attack the front end! If you missed part 1, you are going to want to catch up by  clicking here

With the main outside roll cage tubes bent up, we moved on to the two upper cross braces. Here we are coping them to ensure a nice tight fit for welding

With the main outside roll cage tubes bent up, we moved on to the two upper cross braces. Here we are coping them to ensure a nice tight fit for welding.

We made two of the cross brace tubes and tack welded them in place. Now it is starting to look like a roll cage.

We made two of the cross brace tubes and tack welded them in place. Now it is starting to look like a roll cage.

Here's a shot from back showing the slightly lower front cross brace. This is where the windshield will meet up.

Here’s a shot from back showing the slightly lower front cross brace. This is where the windshield will meet up.

With the cross bars tack welded in place we were able to remove the roll cage for final welding.

With the cross bars tack welded in place we were able to remove the roll cage for final welding.

Here it is with the cross bars completely TIG welded.

Here it is with the cross bars completely TIG welded.

With the majority of the work complete on the roll cage we were able to move onto the front end. Here we are pulling apart the front spindle/brake assembly.

With the majority of the work complete on the roll cage we were able to move onto the front end. Here we are pulling apart the front spindle/brake assembly.

We removed both sides and also the steering connecting rod and the 3 tie rod ends. These will be replaced with brand new tie rods

We removed both sides and also the steering connecting rod and the 3 tie rod ends. These will be replaced with brand new tie rods.

With spindle assemblies out we were able to disassemble the brake components. We started by stripping the old paint and surface rust off of the drums and then prepping and painting them.

With spindle assemblies out we were able to disassemble the brake components. We started by stripping the old paint and surface rust off of the drums and then prepping and painting them.

You can see here that the brake pads had served their purpose and were ready to be replaced.

You can see here that the brake pads had served their purpose and were ready to be replaced.

Here you can see a comparison of the newly rebuilt spindle assembly on the left and the one still needing to be rebuilt on the right.

Here you can see a comparison of the newly rebuilt spindle assembly on the left and the one still needing to be rebuilt on the right.

Here are both rebuilt  spindle assemblies, ready to be reinstalled onto the cart.

Here are both rebuilt spindle assemblies, ready to be reinstalled onto the cart.

Here they are with the drums installed, they look better than new!

Here they are with the drums installed, they look better than new!

Once we had the spindle assemblies rebuilt we moved onto addressing the worn out bushings. Here you can see the original bushings next to the new OEM replacement bushings.

Once we had the spindle assemblies rebuilt we moved onto addressing the worn out bushings. Here you can see the original bushings next to the new OEM replacement bushings.

Here is a picture of the new upper bushings in place. This will ensure everything is nice and tight upfront.

Here is a picture of the new upper bushings in place. This will ensure everything is nice and tight upfront.

With all new bushings installed we were able to re install the rebuilt spindle assemblies.

With all new bushings installed we were able to re install the rebuilt spindle assemblies.

We re installed the drum and the brake cables. This cart will now be taken off the lift as we wait for the new parts to arrive. The next cart will be rolled on and it will receive the same thorough treatment.

We re installed the drum and the brake cables. This cart will now be taken off the lift as we wait for the new parts to arrive. The next cart will be rolled on and it will receive the same thorough treatment.

 

 

 

 

 

 

 

 

 

 

 

 

 

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