I am starting my build, need electrical HELP!

mdevere808 · 06-28-2010, 06:16 PM

Hello BGW world:
I am finally ready to put my cart together. I have a new 700Amp controller (FSIP) from Plumb Quick, HD solenoid, HD F+R switch and #4 cables. What I need to know is...do I need and what size resister, Diode, main fuse, and control cuircuit fuse?..I have the basic wiring diagram that I got from the FSIP site today, but I'm just not sure of all the sizes I should be using. ALso since I'm rebuilding a 96 from the ground up and the F+R switch is so large, how have you guys found the fit in the original location to work out? It looks like it going to be very tight in there.

LostHusker · 06-28-2010, 06:30 PM

How big is the new controller? There should be room, your stock environment cover will no longer work, but that's ok. The company you are purchasing the controller from should be able to tell you what size, resistor, and diode that you will need to purchase or recommend. Have you purchased a heavy duty fnr switch yet, you will need one with that large of a controller.

Just reread again, you most likely will want a 3 amp diode. Do a trial fit of the controller and fnr switch to see how it all fits.

dougmcp · 06-28-2010, 06:56 PM

Are you making the cart 36v or 48v?
Resistors are for 36 volt: 220-250 ohm, 10 Watt or 48 Volt: 470 ohm, 10 Watt
A 3 amp diode should work for your purposes. The stripe on the diode goes to the positive side.
The F-N-R switch on that cart is mounted over on the passenger side in front of the controller. There is an extension rod that runs from the centered lever across to the F-N-R.
Not a really good picture but the rod is at the top of the picture:

dougmcp · 06-28-2010, 06:58 PM

Double post oops......

mdevere808 · 06-28-2010, 07:15 PM

Sorry about the double post folks, I wasnt sure if the pics got on or not.
Yes I am making it a 48 volt cart. I like the F+R switch in front of the controller, But where would I find the linkage rod and hardware to mount it?

By the way thanks everyone for the help. I have been waiting for a long time to start this project and I know I coulnt do it without coming here..Its my first time..

dougmcp · 06-28-2010, 07:20 PM

I don't know where you live but I would make friends with an EZGO dealer there. He should have a bone yard where you could get most of the pieces you need for cheap.
Online there is this place for used parts Called Parts-4-Carts, the website is that minus the dashes, their phone number is: 1-800-262-6861
If you need any new parts our sponsors are knowledgeable and competitive: http://www.buggiesgonewild.com/site-sponsors.php

LostHusker · 06-28-2010, 08:10 PM

Here is one pic of a fnr assembly for ya, let me find one more. In the second pic you can see better, but don't do what I did, the silver tab that connect to the fnr handle is upside down, it caused me a bunch of headaches trying to figure that one out.

mdevere808 · 06-28-2010, 08:24 PM

Hey again guys
I really like the F+R switch mounted like that. But I dont know where to find the parts to make this setup. I did look at the site Parts-4-Carts and others, but this seems like a custom thing. Did you guys modify the old F+R switch in its original position and make up the connecting rod?
By the way here are a few more pics...I have been pouring hours into this, and now I have the body out for paint and parts comming in...I'm really excited, But I'll be nervous until I can get it moving.

Thanks again guys

LostHusker · 06-28-2010, 08:34 PM

You are missing the mount for the fnr handle to mount to, look at my pic then look at yours. I have highlighted the area of concern.

rabbitreborn · 06-29-2010, 01:20 AM

you did the silver GE 700 AMP controller right? are you trying to retain the "stock" look or can I offer up an alternative? Excuse the wiring "mess" in this photo, it got cleaned up before I sent it to the customer but I forgot to take a pic of the cleaned up look......

06-28-2010, 06:30 PM	#2
LostHusker Just one day at a time Join Date: Sep 2009 Location: South TX Posts: 8,650	Re: I am starting my build, need electrical HELP! How big is the new controller? There should be room, your stock environment cover will no longer work, but that's ok. The company you are purchasing the controller from should be able to tell you what size, resistor, and diode that you will need to purchase or recommend. Have you purchased a heavy duty fnr switch yet, you will need one with that large of a controller. Just reread again, you most likely will want a 3 amp diode. Do a trial fit of the controller and fnr switch to see how it all fits.

06-28-2010, 06:56 PM	#3
dougmcp Gone Wild Join Date: Mar 2009 Location: Roseville, CA Posts: 2,757	Re: I am starting my build, need electrical HELP! Are you making the cart 36v or 48v? Resistors are for 36 volt: 220-250 ohm, 10 Watt or 48 Volt: 470 ohm, 10 Watt A 3 amp diode should work for your purposes. The stripe on the diode goes to the positive side. The F-N-R switch on that cart is mounted over on the passenger side in front of the controller. There is an extension rod that runs from the centered lever across to the F-N-R. Not a really good picture but the rod is at the top of the picture:

06-28-2010, 07:20 PM	#6
dougmcp Gone Wild Join Date: Mar 2009 Location: Roseville, CA Posts: 2,757	Re: I am starting my build, need electrical HELP! I don't know where you live but I would make friends with an EZGO dealer there. He should have a bone yard where you could get most of the pieces you need for cheap. Online there is this place for used parts Called Parts-4-Carts, the website is that minus the dashes, their phone number is: 1-800-262-6861 If you need any new parts our sponsors are knowledgeable and competitive: http://www.buggiesgonewild.com/site-sponsors.php

06-28-2010, 08:10 PM	#7
LostHusker Just one day at a time Join Date: Sep 2009 Location: South TX Posts: 8,650	Re: I am starting my build, need electrical HELP! Here is one pic of a fnr assembly for ya, let me find one more. In the second pic you can see better, but don't do what I did, the silver tab that connect to the fnr handle is upside down, it caused me a bunch of headaches trying to figure that one out.

06-28-2010, 08:34 PM	#9
LostHusker Just one day at a time Join Date: Sep 2009 Location: South TX Posts: 8,650	Re: I am starting my build, need electrical HELP! You are missing the mount for the fnr handle to mount to, look at my pic then look at yours. I have highlighted the area of concern.

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06-28-2010, 06:58 PM	#4
dougmcp Gone Wild Join Date: Mar 2009 Location: Roseville, CA Posts: 2,757	Re: I am starting my build, need electrical HELP! Double post oops......

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