ezgo console golf ball cover printable template

txdm

The attached pdf is a printable template for making a cover for the golf ball cubby on the console. It is based on an '01 txt, and it should be the same for most '96 and up models.

The dimensions are: 7-5/8" x 2-1/4" with 9mm corner radii.

After printing it out, check the width to be sure your printer settings did not scale it down or up.

Also, there are two points marked at the bottom for screw holes to secure it to the 1/4" recessed ridge. There are three up on the page. I suggest trying it with cardboard first to get an idea of fitment and where you want any instrument holes to go.

Attached Files

ezgo-console-cover.pdf (53.6 KB, 0 views)

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

NoleFan

Thanks, I may actually use this since I don't currently plan on adding a traditional radio.

Have you used the template? What did you make it out of?

txdm

I'll probably be using some black ABS I have laying around for mine. I'll post pics when it's done.

Here's some other potential materials:

• Thermoplastic: There's even a 100% recycled plastic that is heat-formable like kydex or ABS on Amazon.
• Backside of a retired license plate (the printed kind, not embossed).
• Old cloth and paper layered with epoxy resin/hardener a.k.a. Micarta
• Thin plywood with a varnish or paint
• corrugated plastic (political yard signs)

Always do a test one with cardboard first.

orangeman6

Thanks for posting. I only wish it would have been a couple of weeks ago. Used some heavy poster board to make a template for mine. Cut, trim, cut, trim....finally got it right, but would have been a lot quicker with your template.

orangeman6

Another thought that may help: I cut the plastic away that held the balls, but left about 1/2 inch of it on the top. I then heated that piece up enough to bend it out. By doing that, you get something to attach your cover piece to at the top.

pwgunny

Thanks. I'll be needing this soon.

txdm

Here's a light walk-thru of making two console covers from earlier today. I am not a professional by any means... but I love to DIY stuff and learn.

Using 1/16" black ABS from here:
https://www.amazon.com/gp/product/B0002ZPPLW

1/16" is easier to work with, but its not as rigid as 1/8" if you are going to put heavy things in it or have areas that are thinner than 1/2" wide.

I used a table saw to cut the blanks. 2-1/4" x 7-5/8"


One of the console covers will go on an '87 Marathon. It's the same size cover, but will have large tabs on the sides to secure it to the golf tee holes. I use a white charcoal pencil to rough in the tabs around the template.


A coping saw is handy for cutting. To support the plastic while sawing, I put it just off the edge of the table and cut a little then scoot it out as I go. Just go slow with it.


Next I lay the template back on and use the pencil or chalk to color in the part that will be removed for the corners. (Sorry for the bad focus)

I used a belt sander to remove the corners. You can use a dremel, saw, or even a hand file. When you use a belt sander or dremel, you'll want to take the majority of the corner off then clean up the melted "slag" that forms before doing the final rounding off.

continues...

txdm

Next is the instrument holes. Sometimes they come with a cardboard template, sometimes not. As long as there's a good bezel to cover the hole, it's not too critical. Just try to get it straight/parallel along the longest sides. Note that the screw holes are drilled from the paper template here too.


Here's the best thing about 1/16" abs... you can use a cruddy old soldering iron or wood burner to melt your holes. With 1/8" you gotta do a lot of fiddling around with the coping saw. Be sure to melt plastic outdoors and with a fan or breeze blowing the fumes away.


Just like before, use a knife to clean up the "slag" that forms on the edges from melting it. It's good to do the instrument holes at the very last, so you can slowly adjust them until the instrument fits tightly and not have to remove it to do something else before installing the panel.

Here's the Marathon panel with a light switch and volt meter:



And here's the TXT panel with just a meter:

mike484

Looks good. I plan to also cut one out of the ABS and glue it over the tee holders, they are ugly as sin.

agpfl

Thanks. Template was a perfect fit. Now just have to figure out what material to use.