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Unread 06-24-2019, 08:51 AM   #1
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Default 2004 TXT PDS redo: Immortan Joe

Hi All,

As pointed out by Yurtle I have an addiction. This is the other project cart that I am working on.

Joe1.jpg

Yes, it was a KOA cart. Well maintained. Very little rust on the frame. Motor and controller are not working. Don't really care as they are getting removed anyway.

Joe2.jpg

I am always amazed at how much sand a cart can hold on its frame and under the floor mat! I swept up enough to make a sandcastle!

Contemplating:

1. Navitas TAC2.0 600amp controller w/ 5kw AC Motor.
2. Long travel kit w/ disc breaks.
3. 23" wheels.

Cheers,
Impaled
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Unread 06-24-2019, 07:18 PM   #2
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Default Re: 2004 TXT PDS redo: Immortan Joe

Trying to source Ausco rear disc breaks in Canada is proving a challenge. Even the heavy duty Ausco drums are hard to find in Canada. Good supply of them in the US but, the 250$ shipping here is well, insane. :(

I want the Ausco product as my current setup keeps eating the OEM hubs. Too much torque. If I put the 5kw motor and controller in it will surely shred them.

I have the Jakes Long Travel kit for it and the front disc breaks. But, that won't help with my shredded hubs in the back. :(

Any suggestions for other options for better hubs that won't shred?
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Unread 06-24-2019, 09:16 PM   #3
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Default Re: 2004 TXT PDS redo: Immortan Joe

Quote:
Originally Posted by Imapled View Post
Trying to source Ausco rear disc breaks in Canada is proving a challenge. Even the heavy duty Ausco drums are hard to find in Canada. Good supply of them in the US but, the 250$ shipping here is well, insane. :(

I want the Ausco product as my current setup keeps eating the OEM hubs. Too much torque. If I put the 5kw motor and controller in it will surely shred them.

I have the Jakes Long Travel kit for it and the front disc breaks. But, that won't help with my shredded hubs in the back. :(

Any suggestions for other options for better hubs that won't shred?
Crazy idea. Anyone near the border wanna make $125?
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Unread 06-24-2019, 11:18 PM   #4
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Default Re: 2004 TXT PDS redo: Immortan Joe

Quote:
Originally Posted by yurtle View Post
Crazy idea. Anyone near the border wanna make $125?
I believe I can have stuff shipped to a UPS store in Buffalo and pick it up myself at the store.

Sad thing is that it will end up costing me more than 125$ if I do it because I will have to go to Cracker Barrel. Then to Target... Then to Chillis.. Then I will stop @ Casino Niagara on the way home... All round an expensive endeavour. :)
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Unread 07-03-2019, 11:47 AM   #5
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Default Re: 2004 TXT PDS redo: Immortan Joe

Welcome to the Jungle... We got fun and games...

The axle on my main cart I am currently driving (Mad Max) had some issues so I pulled the one off this cart to replace it with. The working cart is at my trailer park and I couldn't get it back so I figured an axle swap was in order.

Everything worked fine but, changing the whole rear end in the dark of night, in the grass, covered in ants and mosquitos wasn't fun. It got done with the help of two other people. ATV jack helped a lot as I was able to take the whole axle out with the motor still mounted.

So I took the 1996 axle home with me to dissect to see what was wrong...

Axle1.jpg

I figured I had stripped the hub but, nope... Bearings...

Bearings1.jpg

Everything is fine with the exception of the bearings. Which was good news.

Pulling the axles without a slide hammer was interesting. I did the reverse hub thing and it worked for one. Didn't work for another.

I made a make shift slide hammer to do it. I attached the pulled axle to the other one via a long 15/16 nut I had and drilled a hole in a block of wood. Put the wood on the axle and put a vice clamp on the axle. Bang bang and it came out.

Again, no seal puller so I used one of the battery tie downs from my RXV. They have a nice hook on the end a thread on the other end... Put the hook end in... Drilled a block of wood, put on a nut and huge washer and bang bang... out came the seals.

My ring pliers suck. Need to buy better ones. The tip broke off on the last inner ring. Ugh.

Currently cleaning and painting the old axle. Looks brand spanking new. I wasn't planning on touching this PDS cart until the RXV was done... But, when the wife said "Oh great now we have three broken down golf carts..." I had to shift my attention.

Cheers,
Impaled
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Unread 07-03-2019, 07:14 PM   #6
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Default Re: 2004 TXT PDS redo: Immortan Joe

Another option to banish the ezgo drum problem is getting Yamaha G22e hubs and drums. Direct replacement, no mods needed.
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Unread 07-23-2019, 08:23 AM   #7
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Default Re: 2004 TXT PDS redo: Immortan Joe

Quote:
Originally Posted by cgtech View Post
Another option to banish the ezgo drum problem is getting Yamaha G22e hubs and drums. Direct replacement, no mods needed.
Thank you for the suggestion! Parts ordered!
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Unread 07-23-2019, 08:35 AM   #8
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Default Re: 2004 TXT PDS redo: Immortan Joe

Update on this build now that I am done with the RXV... (This one was on pause.)

I ended up with a spare 3.3kw RXV motor and I noticed that the bolt pattern is the same on my TXT axle. So that got me thinking... Why not put this RXV motor (sans break) on my TXT rebuild?

I was planning to put a Navitas TAC2 600amp and a 5kw motor on this cart but, noticed that the plugs for the bearing encoder and thermal sensor on RXV motor appear to match up in the Navitas specs for the TXT48 speed sensor and thermal sensor wire harness kit.

Will need to put in a TXT48 wire harness but, was planning to do that anyway for the AC conversion. Navitas is making a PDS adapter for the TAC2.0 TXT48 but, I have the cart apart so I am just going to change the wire harness.

Just need to convince Navitas to make a custom profile for the motor setup for me. :)

https://docs.wixstatic.com/ugd/86af4...8ff2fd1599.pdf

RXVmotoronTXT.jpg

Could be an interesting mod if I am able to pull it off. :)

Cheers,
Impaled

PS: Ya I know the motor is on wonky. I was just fooling around when I took the pic. Would mount properly. :)
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Unread 08-11-2019, 10:26 PM   #9
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Default Re: 2004 TXT PDS redo: Immortan Joe

Hey Everyone!

So it has begun!

it-has-begun-1.png

I sold my RXV and my TSX3.0 600amp w/ Navitas High Performance Motor "DCS" cart. So I took the proceeds of those carts and dumped it all into this one.

Parts list:

1. Navitas TAC2.0 600amp AC Controller.
2. Navitas 5kw 3phase AC Motor.
3. Navitas On the Fly Programmer
4. 6x8v Battery Set
5. Jake's 6" Long Travel Kit
6. Jake's Hydraulic Front Brake Kit
7. Mad Jax 2014 Inferno Red Metallic Body Kit
8. 23" Tires on Chrome Rims
9. Various things like steering wheel, graphite style dash kit, USB charge part (3.0 high speed), 12v accessory plug, 30amp Downstepper, Undermount Light Kits, etc... etc... etc...
10. Black roof
12. Madjax 150 Rear Seat
13. Custom Black with Red inset seat covers for front and back.
14. Custom cut "Mad Max" floor mat. (Black with grey cutout.)
15. Custom cut "Mad Max" front license plate (metal).

Continued...
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Unread 08-11-2019, 10:31 PM   #10
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Default Re: 2004 TXT PDS redo: Immortan Joe

The Navitas TAC 2.0 600amp and 5kw Motor Kit for PDS carts... Here is a photo of everything that comes in the kit:

1.jpg

The motor is impressive! Here is it up close and personal:

2.jpg
3.jpg
4.jpg

Here is a dry install of the TAC2.0 600amp, PDS wire harness adapter, speed sensor and thermal sensor adapter and the On The Fly programmer.

5.jpg

Continued...
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