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Gator TH 6x4 engine swap - 24 HP Honda  


Joe Gambino
(@joe)
Moderator Admin
Joined: 5 years ago
Posts: 62
Topic starter  

Gator TH 6x4 - around 05 model. These little guys are SUPER low to the ground and rated to carry 1000 lbs in the bed and 2 people. Locking diff, 4wd (back 4), and simple to work on. They're great, and there is nothing else quite like them.

The bad? One of the worst engines kawasaki ever made is in here. This one is about due for its second complete rebuild in just the 500 hours of use I've put on it. Unpressurized oil system,  poor crankcase contamination record (fuel entry), proprietary John Deere parts and information... the list goes on. 

The solution? Put in a normal motor. One with an oil pump. And in this case, 39% more power than stock.

About to go under the knife!

 

 

1613024015-20210131_085033.jpg

-The dude who started RogueFab
4Runner Build thread: https://www.roguefab.com/forum/projects-and-builds/rogue-fabrication-4runner/


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Ambroze
(@phanboifabrication)
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Joined: 2 years ago
Posts: 27
 

excited to see how this turns out!


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Joe Gambino
(@joe)
Moderator Admin
Joined: 5 years ago
Posts: 62
Topic starter  

Here is the new engine!

Honda claims FI-like fuel efficiency. I'm just excited for a pressurized oil system and no TSBs about fuel getting into oil and how that is "normal"!

 

1613183999-20210131_085700.jpg

-The dude who started RogueFab
4Runner Build thread: https://www.roguefab.com/forum/projects-and-builds/rogue-fabrication-4runner/


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Joe Gambino
(@joe)
Moderator Admin
Joined: 5 years ago
Posts: 62
Topic starter  

Old engine is out (takes an hour at a relaxed pace). New engine dropped in, rubbed right frame rail, so I bent it outward. You can see the bend. It isnt enough. I have to move that frame lip/edge (cut and weld). 

I bought a "repower kit" for this. The kit was supposed to be a bolt in affair other than drilling a few holes and some light trimming. It is not well thought out at all. Using it the way they recommend would be a hack job :/ this rig has a 1000 lb cargo payload and a low frame (drags on logs and such at times). Cutting the whole vertical component off one side of the frame is not okay with me. 

Fabrication to follow!

 

You can also see the muffler mounting plate I welded on. 

1613708570-20210131_154701.jpg

-The dude who started RogueFab
4Runner Build thread: https://www.roguefab.com/forum/projects-and-builds/rogue-fabrication-4runner/


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Joe Gambino
(@joe)
Moderator Admin
Joined: 5 years ago
Posts: 62
Topic starter  

I bent the frame lip down flat first. 

 

1613832120-20210210_094553.jpg
 
 
Next I cut the corners and flap wheeled all the paint off where I plan to weld. I bent up some 2" x .120" A36 flat bar to take the rail around the profile with some overlap.
 
 
1613832273-20210210_101857.jpg

-The dude who started RogueFab
4Runner Build thread: https://www.roguefab.com/forum/projects-and-builds/rogue-fabrication-4runner/


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Joe Gambino
(@joe)
Moderator Admin
Joined: 5 years ago
Posts: 62
Topic starter  

My only welder in the garage is a TIG. Normally I would MIG this kind of high-gap dirty stuff. Came out fine for tbe application though!

 

 

1613917592-20210210_110245.jpg

-The dude who started RogueFab
4Runner Build thread: https://www.roguefab.com/forum/projects-and-builds/rogue-fabrication-4runner/


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