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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 08-17-2011, 06:34 PM   #1
derekbooth
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Default '96 EZGO (re)build

Been at this for a month or so and all of the feedback on this forum has been totally invaluable! I've posted pictures throughout several threads to get me past roadblocks, but since it has become evident that this is going to be a fun little project that will likely last forever, I thought I should start my own "build thread".

Sidenote: And to think I had this cart up for sale on craigslist to get some quick extra cash for a down payment on a house. A month later, not only am I with what looks and runs like a totally different cart, I'm happy to announce my wife and I are putting an offer on a new home tonight too! Patience is proving, as always, to be a virtue.

So here is the before picture. Not a bad looking cart right? Fortunately for me, my wife hates the color red, so I got the green light on tearing this mother apart :)



What started as an idea to simply re-upholster and maybe paint, turned into a much more involved project:
  1. Re-Upholster Seats
  2. Paint Front & Rear Cowl
  3. Replace bagwell liner w/ truck bed coating
  4. Rust-proof & paint chassis
  5. And on...
  6. And on...
  7. And on...
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Old 08-17-2011, 06:36 PM   #2
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Default Re: '96 EZGO (re)build

So here are the front & rear cowls painted (with krylon fusion black gloss)...





...with duplicolor truck bed liner sprayed into bagwell:



Highly recommend this by the way!
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Old 08-17-2011, 06:38 PM   #3
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Default Re: '96 EZGO (re)build

Here's a picture of a really dirty chassis (note the new 22" tires by the way!):



Here's a really clean, ugly chassis:



Here's a really clean, primered & rustproofed (rustoleum) chassis:



Here's a really clean, primered & rustproofed AND painted (also rustoleum) chassis:

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Old 08-17-2011, 06:40 PM   #4
Coltf1991
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Default Re: '96 EZGO (re)build

Looks good. We need more pictures....
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Old 08-17-2011, 06:48 PM   #5
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Default Re: '96 EZGO (re)build

Here's the cart mostly re-assembled. The backrest is on the cart now, I just haven't taken any pictures yet



The rear seat kit is re-upholstered (with the exception of the backrest, which I'm going to have a professional do for me), but I'm in the process of rust-proofing and painting this as well. No hurry in getting this back together.

And 10 days ago on a spur of the moment decision, I sent this guy:



...to South Carolina for a Plum Quick upgrade. And today...



I'm happy to report that I clocked the cart at full charge PRIOR to the BANDIT upgrade from PQ at 14MPH (stock controller... for now) and today, after the batteries sitting without any charging for 10 days, I'm clocking 19MPH. About the 30% increase in speed advertised! Batteries are charging right now, so I'm eager to see if I can get another 1-2 MPH out of it after the charge
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Old 08-17-2011, 06:58 PM   #6
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Default Re: '96 EZGO (re)build

And next on the list of things to do:
  1. Install the new steering wheel that is currently en route to me
  2. Install the new access panel purchased form Golf Cart King, also currently en route to me
  3. Get new solenoid/controller from ScottyB (Alltrax 400 or 600. I'm on the fence. Anyone have experience, good or bad, with a 600amp controller + Bandit upgrade?)
  4. Relocate controller by mounting to underside of access panel
  5. Upgrade to 48V using newfound space beneath front seat
  6. Get a long travel lift kit (thinking Jake's, but open to other suggestions. Also looking for feedback on some good performance shocks)
  7. Replace the bullet headlights with some KC HiLites
  8. ...I'm sure I will think of more ways to "invest" some money into this project :)
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Old 08-17-2011, 07:00 PM   #7
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Default Re: '96 EZGO (re)build

Quote:
Originally Posted by Coltf1991 View Post
Looks good. We need more pictures....
Haha... you REALLY like pictures!!!
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Old 08-17-2011, 07:07 PM   #8
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Default Re: '96 EZGO (re)build

Yes I do like pictures and so does everyone else here. Build looks good so far! Mounting the controller under the access panel and not to the heat sink will void your warranty. Just something to think about.

What access panel did you get? Stainless or diamond plate?
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Old 08-17-2011, 07:15 PM   #9
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Default

Quote:
Originally Posted by Coltf1991 View Post
Yes I do like pictures and so does everyone else here. Build looks good so far! Mounting the controller under the access panel and not to the heat sink will void your warranty. Just something to think about.

What access panel did you get? Stainless or diamond plate?
Got the black powder coat. Alltrax makes a heat sink kit that is much more compact than the stock heat sink. I can't imagine that using their heat sink would void their controller warranty???


---
I am here: http://maps.google.com/maps?ll=33.686938,-117.245856
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Old 08-17-2011, 07:19 PM   #10
Coltf1991
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Default Re: '96 EZGO (re)build

Quote:
Originally Posted by derekbooth View Post
Got the black powder coat. Alltrax makes a heat sink kit that is much more compact than the stock heat sink. I can't imagine that using their heat sink would void their controller warranty???


---
I am here: http://maps.google.com/maps?ll=33.686938,-117.245856
Well as long as you are using there heat sink or any heat sink you will be fine! Thought you were gonna run it naked! Lol

Check out my build thread.
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