1991 EZGO Marathon Rebuild

fire4034 · 12-13-2012, 12:18 AM

Well I am ready to get started..."GULP". I recently purchased this 1991 EZGO Marathon that had been converted to a 3x12 36 volt system. It runs fine on flat ground, but just stops on ANY steep incline if you don't have momentum. After getting input from several of you I have decided to start the tear down process and see how it goes. I will be using the cart at our campground which requires electric only and 10-15 (ish) mph speed limit. We do have several long hills that are fairly steep. I am thinking I want to go frame up restoration and with the help of my daughter (10) and son (12), hopefully we will have some fun along the way.

I will show some before and after photos below of what I started with and my initial tear down. I am leaning toward 48v upgrade (conversion) from Scotty. and while I am at it...lift, wheels, tires, radio, rear seat, windshield etc... So I got most of the old wiring and stuff out I am going to work more on stripping things down tomorrow. I hope to get it done and start looking at rebuild parts soon. I can see I am going to have to fabricate or (replace) whatever...the battery tray that is basically gone. I guess the one question I have is...

Am I biting off more than I can chew here? I know I can purchase and replace / upgrade most parts, but my main concern is the body around the battery box area which looks good from outside, but I just don't know.

I don't mind doing the work, or it being a slow process. I just want to know that when I am done it will be awesome! So if there is some reason to not do this project (With THIS cart) because of anything you all see...PLEASE give me your thoughts.

Pic1: Before
Pic2: Before Battery Box
Pic 3: Before F/R Switch
Pic 4: After Battery Box / Tray
Pic 5: Battery Tray & Front of Cart Body

Thanks, Frank

fire4034 · 12-13-2012, 07:06 PM

Well, day two seems to have me a little worried... It seems like there is a lot of rust and damage underneath as I tear things apart. I am not worried about doing the work, I just need SOMEONE on here who has done this type of work before to tell me it is possible. I guess I am asking for anything you guys see that would tell you "oh no, that's a bad idea".

I have come to the realization that this thing is going all the way to the frame and starting from scratch :-)

So in the pics I have the following questions.

1. Where my screwdriver is in the picture, is that supposed to be connected or is it not...I assume not and that is why they run the black floor material up on to the battery box?

2. Can I easily find the plastic clips that look like rivets to replace these if I break them taking it apart? What is the best way to get them out?

3. How do I attack the front end removal? I remember seeing a post a one point that talked about removal of the dash or cup holders first then go from the front?

Any help or opinion on this project is appreciated since this is my first cart project.

Thanks, Frank

wide'iwas · 12-13-2012, 09:41 PM

I just did this to my 92 marathon..

1. Yes there is a gap between the floor mats and the back wrap around anti scratch tape.

2. To remove the front clip the are 7/16th bolts if you look through the dash board you will see them ...you will need 2 wrenches head on other side ..or 2 people

3. To remove drink holder drill out center of plastic tickets

4. Molding on fenders cut the back of the Christmas tree and push out

keep in mind that the molding for the rear mud guards are no longer available so try not to destroy them use a heat gun to remove and reinstall I was able to save all mine and reinstalled them

hope this helps

wide'iwas · 12-13-2012, 09:46 PM

also you should post this on the ezgo gas side of forums a lot of us only have gas and don't check in on this side much...just a idea

thanks

fire4034 · 12-13-2012, 10:38 PM

Well as I removed all of the rear body parts, I found this aftermarket engineering? Would they have put this in because a shock was bad and they didn't want to replace? Or maybe some other problem that required strengthening that area? (and oh yeah taking out all the suspension from the drivers side of the cart!).

Well the front panel where battery box meets floor pan is rusted out. I guess I will have to redo the lower part. It is fine on sides and at the turns so maybe it will call for some diamond plate across the front at the bottom

I will keep on tearing down! lol

Frank

fire4034 · 12-13-2012, 11:41 PM

Just figured out why they may have put this piece of angle in here between frame and spring mount... Check out the picture below, the entire spring on driver side appears to have been broken! Looks like they just welded (if you can call it that) the spring back together with some scrap steel. Wow!

racin161 · 12-14-2012, 08:32 AM

Now that's REDNECK

scottyb · 12-14-2012, 09:31 AM

Looks a pr of rear springs will fix it

heaton · 12-14-2012, 10:29 AM

Frank,

Looks like we are reading the same book but are on different pages. Attached are some pics of my 92 Marathon. This site is fantastic for cart info, keep us up to date with the build.

Harvey

Gonkulor · 12-15-2012, 02:43 AM

Hello Frank.

You got yourself a project for sure.

Front cowl removal sticky from the electric EZGO section http://www.buggiesgonewild.com/elect...l-removal.html

I did a frame up restore on my 93 Marathon. I made new battery trays but if I had to do it again I would just buy the replacements. I also had to replace one of my floor cross beams. Your project is very doable depending on your skill set and resources. Replacement metal is relatively cheap but time may be another factor.

The beam I replaced was the one at the front of the battery box. I also had to weld frame patches where the battery vapors had eaten the frame. My only mistake made when fabbing new battery trays was not calculating the space my frame patches took. My batteries are a TIGHT fit.

Good luck man, and ask all the questions you can think of. If we can help you not make mistakes we have? I'd be proud.

Shon

12-13-2012, 09:41 PM	#3
wide'iwas Getting Wild Join Date: Aug 2012 Location: lake villa, ILLinios Posts: 98	Re: 1991 EZGO Marathon Rebuild I just did this to my 92 marathon.. 1. Yes there is a gap between the floor mats and the back wrap around anti scratch tape. 2. To remove the front clip the are 7/16th bolts if you look through the dash board you will see them ...you will need 2 wrenches head on other side ..or 2 people 3. To remove drink holder drill out center of plastic tickets 4. Molding on fenders cut the back of the Christmas tree and push out keep in mind that the molding for the rear mud guards are no longer available so try not to destroy them use a heat gun to remove and reinstall I was able to save all mine and reinstalled them hope this helps

12-13-2012, 09:46 PM	#4
wide'iwas Getting Wild Join Date: Aug 2012 Location: lake villa, ILLinios Posts: 98	Re: 1991 EZGO Marathon Rebuild also you should post this on the ezgo gas side of forums a lot of us only have gas and don't check in on this side much...just a idea thanks

12-14-2012, 08:32 AM	#7
racin161 Gone Wild Join Date: Feb 2011 Posts: 1,515	Re: 1991 EZGO Marathon Rebuild Now that's REDNECK
racin161 Gone Wild Join Date: Feb 2011 Posts: 1,515

12-14-2012, 09:31 AM	#8
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,417	Re: 1991 EZGO Marathon Rebuild Looks a pr of rear springs will fix it

12-15-2012, 02:43 AM	#10
Gonkulor Astronautilator Join Date: Sep 2011 Location: North Idaho Posts: 1,494	Re: 1991 EZGO Marathon Rebuild Hello Frank. You got yourself a project for sure. Front cowl removal sticky from the electric EZGO section http://www.buggiesgonewild.com/elect...l-removal.html I did a frame up restore on my 93 Marathon. I made new battery trays but if I had to do it again I would just buy the replacements. I also had to replace one of my floor cross beams. Your project is very doable depending on your skill set and resources. Replacement metal is relatively cheap but time may be another factor. The beam I replaced was the one at the front of the battery box. I also had to weld frame patches where the battery vapors had eaten the frame. My only mistake made when fabbing new battery trays was not calculating the space my frame patches took. My batteries are a TIGHT fit. Good luck man, and ask all the questions you can think of. If we can help you not make mistakes we have? I'd be proud. Shon

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