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



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Old 08-17-2012, 10:45 PM   #1
Busted Knuckles
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Default 1991 Ezgo Marathon electric to gas conversion

Well I started the conversion today on my 1991 Ezgo marathon. Since I got the cart used It needed to go through it with a fine tooth comb.

First I removed all the electronics.




Then stripped the cart down to frame.
Scrubbed and cleaned all the dust off of every thing.
Got some sand paper and a wire brush and went to town.
Coated the chassis with Ospho then painted with HD auto enamel by brush for the durability of thick coats.










Took some measurements and removed the inside supports from the battery box. Cleared every thing out of the way for the drop floor I am bolting in. I left the perimeter of the battery box because it will no interfere with the drive train and it gives me a sturdy frame to bolt to. If you cut it in the right spots the frame doesn't loose is strength. With this method anyone can do it with simple house hold tools. The only welding involved is tacking the sprocket and hub on the spline drive but you can carry the axle down to a weld shop for that. The sub floor the motor will be mounted to is some floor material out of a air plane. The material is composite, thick, and very light weight. The floor will be suspended 2" from the battery tray frame by grade 8 fasteners.

You can see the parts of the frame I left for the motor mounting.








I have to get some 1" spacers for the front. The passenger side front tire rubs on the steering linkage.







These things are 11" wide..



I like the tread.
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Old 08-17-2012, 10:45 PM   #2
Busted Knuckles
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Default Re: 1991 Ezgo Marathon electric to gas conversion

Decided to go through the diff and check bearing and brakes. My diff pan had some battle scars but my baby sledge took care of them.























Dusted off the dash a little. Its still dirty but it looks great all cleaned up...



I will get more pics of progress as I brave this heat. Hopefully when this thing is done it will be like a new frankenstein'd cart. The complete body and top are getting bed liner'd for durability.
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Old 08-17-2012, 11:08 PM   #3
Busted Knuckles
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Default Re: 1991 Ezgo Marathon electric to gas conversion

B=well and I went over the figures and here they are.

Top Speed = 22.60 mph
3600 stock rpm speed = 216000 (engine revs per hour)
0.90:1 = 1.11 overdrive 1 (inside TAV2 caused by pulley sheaves)
0.92:1 = 1.08 overdrive 2 (TAV2 output sprocket 12T sprocket to the 11T on the diff)
12.44:1 = 0.08 rear differential ratio

I am gonna show B-wells work for you can see how to calculate for top speed.

216000(engine revs per hour) *1.11(overdrive 1) *1.08(overdrive 2)*0.08(axle ratio) *69.11(tire circumference)/63360(inches in a mile)=22.60(mph)

And should still have down low grunt.
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Old 09-25-2014, 09:53 PM   #4
toxicwaste29
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Default Re: 1991 Ezgo Marathon electric to gas conversion

Did you ever get this project done? How did it turn out?
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