Gonkulor, The Project

Gonkulor

Hi BGW gang,

My project is underway so I will share my feats and figured starting my thread would help keep objectivity in scope. This way if I'm an idiot I can find out how much in one specific place vs. multiple posts.

I will put all proceedings on my carts own website often, check my signature, and that way I won't always have an active thread. I'm not needing that much attention.

This will give me the ability to let all my far off friends and relatives see what I'm doing. Plus here, I can keep it simpler. Q&A, Facts.

And here we go. 1993 EZGO Marathon, Series motor

Started de-paneling, found lots of rust and a creased bumper, see pix. Bumpers are about $25.

One question, anyone have any measurements on a 93 Marathon? Front and back left to right, diagonally, and vertical measurements? The frame looks straight but if I'm going to go as far as I intend, I might as well check gaps and measurements. I'll check it all as square just how it is.

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BGW

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as350pilot

Looks like fun, keep us updated..

Gonkulor

I think I have come up with a theme, Rat Rod! The Marathons front bezel is sooo boxy that it might work? I'll play with some sketch's, and try to make some kind of front clip to replace the plastic cowl. Maybe nickel plating will be involved.

Otherwise. My Lift kit showed up and I'm going to install it to get a visual in my mind. Then tear everything back apart for powder coat.

Best regards all
Gonk

Gonkulor

Installed the lift kit. The shocks I got for the rear will work very well put the fronts don't compress far enough so there going back and I'll try others.

I did some sketches, see below. I'm definitely no Picasso, maybe more like Warhol.

I may find a Rat Rod forum and ask for suggestions on what junker parts could work with when I start cutting up metal to create the front clip. This rat rod theme could turn into a nightmare. I'm thinking of on old 70's gilson lawn tractor hood might be the front nose and part for top of clip? I don't know. I really just need to go to a few auto salvage yards and roam around looking at fenders, trunks, and crap like that. I might be able to get the wheel fenders of a few older step side style truck beds?

Anywho... This is all I got for the next month or so. I don't think I'll strip everything off till next month when the weather will start shutting all of us Northerners inside, plus I still have my JD with the snowblower attachment. Yes I even drive that to the corner store

Here are the pictures.

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Gonkulor

crude I know

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DOOmsman

The front looks like an Issetta?
Keep us posted.

Gonkulor

Oh no! That is not the look I'm going for at all

Here is where I am at today, and I need help from the group, please.



I'm somewhat worried about two items. First is finding out my Idler Assy upper mount looks bent, picture below. The Idler shaft came out by drifting it down from above. Isn't the shafts upper end supposed to have a collar on it? If it's supposed to have a collar I can weld a washer on it or buy a new one.
Second issue is all the rust, but mostly the hole I found in the mid frame lateral floor beam beneath the front of the seat rail support structure. Again picture below.

Bent Idler mount.

Cart is laying on the drivers side and there is a hole in the beam approx 2" inboard towards the drivers seat.

The drivers side frame segment in the back does look bent to me and I am hoping once I remove the rear bumper, for replacement, the frame will relax back.

Of all the things I am not, which hurts me in this project, is a welder. I have enough friends close by who can weld for me. I will definitely be using their services soon. Sure I can stick two pieces of metal together with a wire feed but nothing I would be happy with.

After all that is said, here are my questions.
1) Idler mount. Should I grind it off, heat it up and beat the living snot out of it back into shape. Then jig it back onto the cart with the Idler assy and have it welded back into place? OR, just buy some new extrusion and make a new angle? Then of course install it the same way as previously mentioned.

2) Floor beam. I doubt this can be purchased so I'll have to plan to fab a replacement. Any idea what type, style steel I should ask for when I go buy some? Can I find extrusion or will I have to cut this piece out and bring it to a shop to have someone dupe it in a break?

3) Frame Coatings. I really want to powder coat the frame but after drilling off all the welds I realized I will be burning a lot of spots in a new finish when the floorpan and lower seat surround panel goes back on too. Is this a big deal? Should I just get everything media blasted and POR15/paint combo it? Maybe that will just have to be a personal decision? Of course I will have the battery tray, mid floor beam replaced and seat support re installed first. Dilemma.

That's where I'm at gang. All help will be greatly appreciated. I put a whole lot of pictures on my carts site if anyone cares to see more.

Best Regards
Gonk.

Gonkulor

I've progressed a fair bit in the last week. I'm planning to buy steel tomorrow for all the replacement pieces.

I tore down my Differential assy.




And I shined it up, smoothed out casting seams and that mfg slag. Getting the unit ready for paint. Still not sure what color I want. Probably going to be gloss black on tubes and Coke red the case and motor.




Finally got the fwd seat support, battery tray, floor beam, and rear bumper off.



I should be close to painting the frame by Oct 15th.

simple man

It's going to look magnificent when it's done! And if you think you have rust, you should see mine I noticed in one of your pics the building your in has bent wood beams. Is it an old quonset hut? Just nosy and curious!

madoc1

looking good gonk. you can do the welding! with a descent mig, even a kid can do it. you may have to grind some bad ones, but what the heck.. after you are done you will find lots of uses for it. and all your neighbors will come visit!