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Unread 12-12-2008, 07:43 PM   #31
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Default Re: Brought home an Ike casualty today

CC-John,
That cart will be BA, with re-gearing and the D395, speed and torque! I bet you hit 27+ and pull the tires off the ground. I didn't notice what controller are you putting in that bad boy? Keep the pics. coming...I'm taking notes. LOL.
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Unread 12-12-2008, 07:47 PM   #32
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Default Re: Brought home an Ike casualty today

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Originally Posted by CC-John View Post
Thanks Mike!!!

I have a list of parts bought so far, right now it's hovering at the $900 level.. The control harness was built from leftover wiring from various boat projects.. It's all marine tinned copper.. All the rusted mild steel hardware (nuts & bolts) is being replaced with stainless steel.. I have a a couple of 5 gallon buckets of SS hardware scavenged from nearly 30 years in the swimming pool business.. The 10" tires & wheels were take offs from my EZGO gasser.. A friend that has an electric motor shop north of Houston is getting the GE D395 motor for me at his dealer cost..

My actual finished cost will more than likely be far less than most folks could do one of these carts for..
Right - O I think it is helpful for others to keep a 'real world' cost list. Granted, you are saving some good coinage from your connections and spare parts.

Factory EZGO - Bad Boy Buggy - Dixie Chopper Mowers
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Unread 12-12-2008, 07:47 PM   #33
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Default Re: Brought home an Ike casualty today

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Originally Posted by BRS View Post
I didn't notice what controller are you putting in that bad boy?
It's getting a 500A Alltrax.. I figure it won't have any trouble converting those Carlisle Turf Savers to smoke!!!
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Unread 12-12-2008, 07:52 PM   #34
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Default Re: Brought home an Ike casualty today

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Originally Posted by mikesmotortoys View Post
Right - O I think it is helpful for others to keep a 'real world' cost list. Granted, you are saving some good coinage from your connections and spare parts.
Being self employed in a service business helps too.. A lot of the electrical connectors and wire gets purchased thru my wholesalers as a "business expense".. It's all stuff I'd end up using on the job anyway, might as well have a little bit of fun too!!
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Unread 12-14-2008, 10:24 PM   #35
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Default Re: Brought home an Ike casualty today

Finally got a rolling chassis today..

Got the bearings pressed onto the new 8:1 gears and assembled the differential.. Rebuilt the brakes, new shoes, cables, and pedal blocks.. Installed the late model DS component mounting plate for the solenoid,and controller.. Mounted the rear axle to the springs, installed the rear wheels, and loaded the batteries... Now it's time to start on making battery cables and install the control harness..

More pics of the progress...
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Unread 12-15-2008, 04:48 PM   #36
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Default Re: Brought home an Ike casualty today

Looking good

Gratifying work isn't it?
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Unread 12-15-2008, 07:10 PM   #37
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Default Re: Brought home an Ike casualty today

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Originally Posted by EZ-GOnewild View Post
Looking good

Gratifying work isn't it?
Thanks!!

I've been wanting to do a "frame-up" resto on a cart for a while.. Ike gave me a chance to get a rebuildable cart for next to nothing.. I couldn't bring myself to spend $800 to $1000 for a cart that was going to be completely torn apart and rebuilt anyway.. Besides when it's finished, I'll have two souped-up, registered, street legal carts.. Doesn't get much better than that!!
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Unread 12-19-2008, 01:44 PM   #38
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Default Re: Brought home an Ike casualty today

Sounds like a hell of a project John! Are new gears difficult to install?

Your buddy doesn't have another GE D395 he might want to sell, does he?
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Unread 12-19-2008, 03:37 PM   #39
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Default Re: Brought home an Ike casualty today

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Sounds like a hell of a project John! Are new gears difficult to install?

Your buddy doesn't have another GE D395 he might want to sell, does he?
I gotta have something to keep me outta the beerjoints!!!

The gears are an easy install if you have a press to remove and reinstall the bearings on the input & idler shaft.. I have a 12 ton hydraulic press in the back of the garage that really came in handy!! If you plan on a gear swap, be sure to get all of the seals and gaskets when you order the gears..

I'm heading to my buddy's shop Monday to see about getting the motor ordered.. All I'll have left to get is the controller to have an operational cart..
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Unread 01-03-2009, 04:03 PM   #40
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Default Re: Brought home an Ike casualty today

Getting closer to having a runnin cart!!!

Got the new control harness installed, along with the new HD F/R switch.. Installed the OEM MCOR conversion kit, and spliced it's harnesses into my new control harness.. Got the new 400A solenoid mounted, along with the fuse holder for the 400A ANL main fuse.. The D395 motor will be in Monday, will get it installed and the cables to the F/R switch connected.. The only thing left to get is the Alltrax AXE 500A controller.. Being able to lay the chassis on it's side sure makes installing all the brake and throttle linkages easier..

Some more pics...
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