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Old 06-10-2017, 08:26 PM   #1
rking1998
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Join Date: May 2017
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Default 1998 TXT Build Thread

I thought I would start a build thread to document what I am doing, to keep me motivated, and to get recommendations/help along the way.

I bought a 1998 EZGO TXT about a month ago with very little knowledge of golf carts. What I actually got was a little less than I thought. I now know that it is a DCS cart.

What was wrong with the cart: First, it had the wrong batteries. I thought that three 12V batteries was just as good as six 6V batteries. What I did not know is that I did not even have golf cart batteries.
IMG_0030.jpg

I now know that three 12V marine batteries definitely does not equal six 6V golf cart batteries. So I took them out.

Second, there was a little rust. Especially the battery rack. If you look at the picture of the batteries, you can see that he PO had wood over the rack and the batteries held in with screws and zip ties. I did not see that on day one...

When I took the cart apart and pushed it outside to pressure wash it, I got to see how much rust there was.
IMG_0066.jpg

I think that the worst of the problem was the battery rack. It had almost rusted through.
IMG_0103.jpg

A new battery rack was quickly ordered. I also ordered 2 gauge cables and the hardware to hold down the batteries.
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Old 06-10-2017, 08:39 PM   #2
rking1998
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Default Re: 1998 TXT Build Thread

So, before I started taking it apart, I did drive it up and down the street a few times. Notes that I took from my test drive are that the cart lacks power on any kind of an incline and the brakes are a little "soft".

I started attacking the brakes by taking the drums off only to find out that the shoes have plenty of materiel on them, but the auto-adjusters are about shot. I took the brakes completely apart and cleaned them. I had to bend the auto-adjusters a little to get them to move back and forth correctly, but the cables needed tightening. I tracked down how to adjust the tension on the cables to the brake compensator. I am assuming that this is not how it is supposed to look:
IMG_0095.jpg

But, using a hole drilled into my workbench to pry with, I managed to work it out to this:
IMG_0097.jpg

Now I have tightened the cable and hopefully when I get the cart running again they will work.
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Old 06-10-2017, 08:52 PM   #3
yurtle
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Default Re: 1998 TXT Build Thread

Don't buy your batteries yet. First, you need to figure out what exact cart you have. Then I'd recommend downloading the owners, parts, and service manuals from the stickies. Finally, decide what you want out of the cart. Do you want torque, speed, or both? Where will you be driving it - paved, gravel, offroad - how hilly is your terrain, will you be carrying three passengers, how hilly is your terrain, how fast do you want it, do you want it to be street legal, do you want larger tires, etc.
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Old 06-10-2017, 08:59 PM   #4
rking1998
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Default Re: 1998 TXT Build Thread

My two gauge cables came in and I was amazed to see the difference between what I currently had and the 2 gauge cables. What I currently have was a mix of 4 and 6 gauge cables.
IMG_0118.jpg

Today, I picked up a new set of Trojan T-105 batteries and put them in the cart. I have not completed all of the cabling yet, but what a change!
IMG_0127.jpg

I had to pay for some core charges because I only had three 12V and they were not golf cart batteries. But, with tax, I think that I got a good deal at $700 flat.

Hopefully I will get to order my Altrax 500amp controller along with the super duty 400amp solenoid on Monday. Next will be 20" All Terrain tires. While I am waiting for those things to arrive, it is time for body work.
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Old 06-10-2017, 09:08 PM   #5
yurtle
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Default Re: 1998 TXT Build Thread

Since you just bought your batteries, you may know a friend/neighbor, who has a dead battery or two laying around. When I bought eight batteries, I only had six cores, but a friend had several diesel engine batteries, so I used them as cores, and got back more than the core charge of a buggy battery.
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Old 06-10-2017, 09:29 PM   #6
rking1998
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Default Re: 1998 TXT Build Thread

Thanks Yurtle.

I have been doing a little research have even had an email conversation with Scottyb about what I am trying to accomplish.

My plan is to use it around the neighborhood and at my son's archery tournaments. My wife, son and I will be riding it and the terrain will be just slightly more hilly than a golf course, but maybe a little off road.

I am thinking 20" all-terrain tires because I don't have to put a lift on it right away (or ever if I don't think I need it once it is put back together). I don't need much speed, but do want torque/power so that I don't think the cart is straining.

With Scottyb's help, I picked the XCT-500 controller combo and eventually the Admiral B-2 motor if my stock 36V motor does not get me where I want to go. I already had a set of 2 gauge cables ordered, so I think that is good to go. I think I will stick with 36V for now with the possibility of going to 42V in the future.

Am I missing anything?
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Old 06-10-2017, 09:31 PM   #7
rking1998
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Default Re: 1998 TXT Build Thread

Quote:
Originally Posted by yurtle View Post
Since you just bought your batteries, you may know a friend/neighbor, who has a dead battery or two laying around. When I bought eight batteries, I only had six cores, but a friend had several diesel engine batteries, so I used them as cores, and got back more than the core charge of a buggy battery.
I asked my friends, but they are not the type that will keep dead batteries laying around. I actually had to go to a couple of places until I found someone who would actually take my batteries as cores at all.
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Old 06-10-2017, 09:47 PM   #8
yurtle
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Default Re: 1998 TXT Build Thread

Funny. I have a "few" redneck friends, that hoard cars, trucks, etc. in their yards, like I hoard electronic parts in my garage.

If you spoke with ScottyB, your build will make you more than happy. I just noticed you were kinda new here, and didn't want you to buy stuff that would preclude upgrading in the future.

I went with 8 - 6 volt batteries, but when it's time to upgrade them, will seriously consider 6 - 8 volt batteries, OR, since I'm only 5 years into my T-105s, I'll seriously consider lithium.
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Old 06-11-2017, 08:53 AM   #9
rking1998
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Default Re: 1998 TXT Build Thread

I appreciate you looking out for a newbie.

I have a little redneck in me, but no more than is allowed by the homeowner's association in my subdivision.
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Old 07-05-2017, 08:23 PM   #10
rking1998
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Default Re: 1998 TXT Build Thread

I guess I am all in now....

My motor seems to have a short and I don't have time to try to fix it before my wife's deadline, so I am trying to order an Admiral Mot-B2. Along with my XCT500 controller, heavy duty solenoid, 2 gauge cables, new wheels, and metallic blue paint job, this will be practically a new cart.

In the installation of my controller, the yellow, red, and blue wires that connect to the two small posts of the solenoid are too short. I would like to attach some extensions, but I cannot figure out gauge the wires are. Can anyone help?
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