Harold Bawlzangya Racing

Harold Bawlzangya Racing

If I only knew what I was doing . . .

Latest

Shipping do’s and don’ts

So I buy a Kawasaki FE290 golf cart engine over the summer, along with a muffler and 2 carbs.  All of that is easily 70 pounds, probably more.  This is how the ass clown ships it – single ply cardboard box with a few pieces of foam.  Here they are in order of un-boxing the engine:

assclownshipping-11_li

assclownshipping-1_li

I wish I could say I made this up, but this is exactly how it looked when I opened the box!

assclownshipping-2

assclownshipping-3

assclownshipping-6

Nice how the carb and oil filter are right next to the side of the box.

assclownshipping-7

Wonder how that could have happened?

assclownshipping-9

Another nice touch – no significant packing between the clutch (which is attached to the crank) and the side of the box.

assclownshipping-8

After many emails back and forth, I got 1/2 of my money refunded.  The guy kept blaming UPS not handling the box carefully enough.  Simply amazing!

So this is how I box up an engine.  Remove all the parts that stick out or can be easily bent up:

properengineshipping17

Plug up all openings:

properengineshipping-3

properengineshipping-4

properengineshipping-5

Remove clutch:

properengineshipping-6

Using a heavy duty, doubly wall box:

properengineshipping-7

Cut-up 3-4 pieces of cardboard and put them in the bottom:

properengineshipping-8

Bag the engine:

properengineshipping-9

Now the time consuming part, cutting up pieces of cardboard and fitting them around the engine to pack it in tightly:

properengineshipping18

With the crank side, I cut out holes in the cardboard to slip over the exposed crankshaft.  That puts any pressure on the side of the engine and not the end of the crank:

properengineshipping-10

properengineshipping-11

The engine is in there nice and tight:

properengineshipping-12

properengineshipping-13

properengineshipping-15

properengineshipping-14

properengineshipping-16

properengineshipping-1

properengineshipping-2

59 minutes later I’m finally done, box weighed in at 79 pounds. Next time I am going to use expanding foam.  That should save a lot of time and weight.

enginpackageddone_li

DPI Charger

For most of the time 12+ years we owned the 1999 Club Car DS, it had the DPI Charger.  We always got 5+ years from our batteries and I gave the DPI charger part of the credit for that (keeping them watered properly didn’t hurt).

I just haven’t had the same confidence in the Club Car charger and OBC.  Plus having the OBC is just one more part that can fail at the wrong time and really screw up plans.  After selling a few more dirt bike parts, I had enough to get another DPI charger.

First step was getting rid of the OBC.

obcremoval-2

Then I pulled the negative and signal wire from the loom:

obcremoval-3

Pulled the grey signal wire out from the loom a littler further back:

obcremoval-4

Cut and shrink-wrapped the signal wire:

obcremoval-5

Next step was removing the plug on the negative charge port wire so it can connect directly the main negative:

obcremoval-7

obcremoval-8

The last step is connecting the white and blue wires together.  Soldered with heat-shrink:

obcremoval-11

Put everything back together and plugged in the DPI.

obcremoval-1

Trying to stay ahead of the IAWPMA

This should keep me in good standing with the IAWPMA (Internet Alcohol Website Picture Monitoring Association) – for a little while at least.

beershot

2090engine-2

2090engine-1

2090engine-3

 

 

Enclosure installation

So the aluminum channel on the perimeter of the roof wasn’t going to make this as easy as I’d like.  There isn’t a lot of material above the slot to get the screw into:

rail

I installed the enclosure rails using the screws provided, but I wasn’t very confident that it would hold up long term.  I did a good job of getting the screw in the center of the channel on this one:

railscrews-1

But I didn’t catch this one my much:

railscrews-2

Considering that these enclosure rails are going to get some stress, I figured something a little more study was in order.  Brass toilet flange bolts will do the trick.  They fit perfectly in the channel.

flangebolts

So the enclosure rails were supposed to be universal in that they had some rectangular and v notches cut in them that would supposedly clear most roof/support combinations.  It was strictly cosmetic, but the cutouts that didn’t even clear anything looked like a hack job to me.

crappynotches-2

crappynotches-1

I added some aluminum flat stock to cover the cutouts, tightened down the nuts on the t-bolts and then installed some rivets on any of the visible screws holes I originally made.  I can live with the way it looks now.

coverdone-5

coverdone-4

coverdone-6

coverdone-3

coverdone-2

coverdone-1

Well that’s not good

brokenleafspring-2

brokenleafspring-1

FE290 muffler

Deep inside the quiet and restrictive FE290 muffler:

fe290muffler-2

fe290muffler-3

fe290muffler-4

fe290muffler-5

fe290muffler-8

fe290muffler-7

fe290muffler-13

fe290muffler-10

fe290muffler-14

fe290muffler-1