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Discussion Starter #1 (Edited)
So I figured I made a thread about my project
This is something that's new for me as I rarely work on a 6x4 let alone a 4x2 ts but here goes.

At work we have a scrap ts frame with a blown gearbox and has been used for parts.
I asked my boss if i could take it as a project and he said yes.

rebuiding the gearbox and motor would cost too much for what is basically already a non road legal machine and I don't know what else is wrong with it.
The only option now is a bike engine.

So what's the plan?
I will be searching for a 650 to 1000cc engine and swapping that with the fe290 powerplant and gearbox.

How?
Don't know yet 😛
But I've been having ideas about putting in a 6x4 sprocket on the axle and putting a go kart axle between the 2 shafts.
Maybe even putting a jackshaft between it and the engine so I can play a bit more with the gearing since I'll be limited on the engine side and can't change the axle side.

I'll be starting work gutting it next week and pics will follow then
 

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Discussion Starter #2
Well iam digging this up from the grave as i have actually started on the ts and have a plan lined up.

I am still going to take out the gear and engine but will downsize the engine to a briggs 18 as found on the xuv 550 bored to 23 with tuning goodness and twin carb
Iam hoping to make around 30+ horsepower

I have ordered a full 1 inch kart shaft and hubs for the rear and will be fitting 10 inch wheels with 25 tires.

I will keep the vario but will make a jackshaft from which i run a chain to the axle.

I have already removed the old rear hubs and plan to remove the gear and engine asap

For the shocks i ordered progressive suspension 17 inch shocks

Some pics:
20190709_165428_1562680913978.jpg
20190709_165411_1562681242302.jpg
 

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Welcome back- thanks for the update
 

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Discussion Starter #4 (Edited)
You dont want to know how we got it here.
I put it on with the forklift and came home and was like uuuuhhh.

I used some ratchet straps to get it on the rails and after that i hooked it to the 415 to get slide it off.

Anyway i found myself a broken new rear vario that i can fix with a new spring.
We installed it and then the customer came after 6 months to finally pick it up and by that time the vario seized up.

I also found a gear input shaft which i will turn down to 5/8 on the non toothed end so i can put a sprocket on it.

Iam mainly mixing and matching some parts to the point where i have everything but the engine.
Once i have a rolling frame i can take the gator to work to find a fitting engine
 

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ט×[emoji769 said:
×� ×רו×למ×;93137]You dont want to know how we got it here.
I put it on with the forklift and came home and was like uuuuhhh.



We installed it and then the customer came after 6 months to finally pick it up and by that time the vario seized up.
How did the vario seize? Moisture(rust)?

Once i have a rolling frame i can take the gator to work to find a fitting engine

On the John Deere Gators Facebook group a member re-powered his 4x2 with a 600cc Yamaha V-Max 100hp Snowmobile Engine...





https://vimeo.com/335519298
 

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Discussion Starter #6
Yeah it basically seized because of water and dirt as it sat open outside for so long.

Repowering it with a snowmobile engine or any engine other than briggs would be more costly and is a lot of added weight.
Ive had tons of gearboxes open and even the little 550 gearbox weighs about the same as a briggs block.

Now considering that the ts is light, very light it would actually have some benefit to remove weight from the rear and less weight also means a better power to weight ratio.
Not to mention the fact that having no suspension and a heavy gator will make your teeth shatter at some point

So instead of getting a huge engine and leaving the gearbox as a dead weight i can take a small briggs and bore it out, tune it and make around 30 40 or 50 hp depending how deep my pockets are

Plus, a briggs with an open exhaust sounds alot better than what he put on 😛
 

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Hopefully you got a chuckle out of my post as that was my intent...
 

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ט×[emoji769 said:
×� ×רו×למ×;93163]Well i was mostly shocked, because for 100hp its pretty slow
Even the rsx goes faster with half that.


I don’t know if other modifications to the Gator where completed? I don’t recall any mention of changes to the gears or Clutch’s
 

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Discussion Starter #10
I see a standard tuff torque gearbox so it should be geared incredibly low.

Meanwhile, i present a ts shaft and a seized hpx clutch.
The clutch is moving now but the spring is out of whack so it needs to be opened and the spring put back in place
20190711_200246_1562866343146.jpg

Some info for homebuilders below which i found out through many moons of searching for parts.
This information is not out here or anywhere as far as i know so i hope someone will be helped by it.

All john deere clutches not made by team industries are basically comet clutches.
I found that the comet 102 xp matches the hpx 855d tx etc clutches almost 100%

Theoretically you can swap 102xp spring but not the weights because they are smaller on the 102.
Using the heavy 102 springs could engage the front cvt later.
I am going to order some springs to try that out later in the project.
This gives some extra tuneability perhaps for the people who want to play with rpms.

The rear vario however has a lot of tuning possibilities if we look closer.
Firstly this vario is an oddball from comet.
It started out all the way from the amt/ts with keyway and you can actually still buy them with keyway although john deere stopped production and they are become very rare soon there are still stocks around.

I found out during this search that it is basically a comet 860 clutch with some tweaking.
This also means that ramps/spring/helix etc from the 780 790 could possibly be used as this one is compatible with those models.
In the most extreme case you could even rivet a 700 series center on and unlock even more options.

Comet is started to become rare these days but if you are looking for parts go look at 6x6 forums or snowmobile sites, theres tons of stuff for cheap.

Long read but maybe someone could use this to experiment on their machine
 

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Discussion Starter #11
I got proven wrong and actually found out that the clutch is in fact a 90d with modifications.

There is enough documentation on the 90d to say for sure that these are in fact one and the same.
This means that also the same tuning guides apply as for the 90d

Screenshot_20190713-125900_Drive_1563011957245.jpg

Here we have the settings for the driven clutch dug up from the backpage of the internet
If i can see correctly john deere has the setting at the standard 12 lbs
Moving the spring to hole 4 could bring this to 22lbs

There should also be different cams available and a brown spring

As for getting the bugger out thats a story for another day because this sucker is on tight so dont do this without proper safety.
I will take it off sometime tomorrow at work
 

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ט×[emoji769 said:
×� ×רו×למ×;93137]You dont want to know how we got it here.
I put it on with the forklift and came home and was like uuuuhhh.



We installed it and then the customer came after 6 months to finally pick it up and by that time the vario seized up.
How did the vario seize? Moisture(rust)?

Once i have a rolling frame i can take the gator to work to find a fitting engine

On the John Deere Gators Facebook group a member re-powered his 4x2 with a 600cc Yamaha V-Max 100hp Snowmobile Engine...





https://vimeo.com/335519298

Ha love it!
I see a tGator race series coming on...
 

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Discussion Starter #14
Out with the old
20190803_121722_1564824116366.jpg
Its unbearable in this 100 degree weather but i really want to get this going

There is some rust but overall it looks like ill be able to salvage it
The battery tray looks the worst obviously
20190803_121701_1564824264908.jpg
20190803_121709_1564824318719.jpg
20190803_121653_1564824337081.jpg

So this means the frame is almost ready to clean, strip, and primer it

Meanwhile i got something new to put into it.
20190721_190417_1564824615813.jpg
Bmw f650 engine says vroom
 

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Discussion Starter #15
Introducing: wheels
20190804_193854_1564937121423.jpg
Just testfitting to see what will work.
The axle is a bit on the narrow side but i could not get anything bigger than 45 inch long shipped so that means i basically said screw it and just ordered whatever and vowed to make it work.
20190804_193902_1564937523070.jpg
At this point iam missing around 6 inches but i can shave 1 inch off the hubs on either side.
I am going to use some skinnier wheels on the front to get everything in line properly.
20190804_193844_1564937642827.jpg
If not i might grab a couple spacers but the narrower setup does look a bit better
And i will most likely grab a couple duro tires in 25x11-10 as i still need some balloon effect for suspension
 

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Discussion Starter #16
The tray under the gastank was rusted so i removed the plate entirely.
20190807_181158_1565191484861.jpg
And i will do the same on the other side
20190807_181221_1565191646320.jpg
I might weld some square tube on the lip of the center plate
 

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Looking good!!
 

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Discussion Starter #19
Looking good!!
Thanks.

Removed some brackets and plates that werent original, someone already started that a long time ago and in doing so grinded away part of the original metal so we are going to need bondo and a lot of it
20190809_141614_1565349532020.jpg
Started sanding the outside tub for a nice coat of owatrol oil.
I couldnt get the c.i.p. here but will put this on any rust spots and cover it with normal spray primer
15653497422632512869818387037757_1565349755024.jpg

I also got 2 dents that worry me a bit as the metal was thicker than i thought.
Guess i need a bigger hammer and more bondo for that
 

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Discussion Starter #20
Fresh owatrol oil
Coated the whole outside of the tub so far and will move forward from here.
You can also see the dent on here, i tried hammering but had not much succes.
20190809_180328_1565363301794.jpg
Also, the sprocket carrier arrived.
20190809_144241_1565363486114.jpg
 
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