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



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Unread 09-15-2008, 06:57 AM   #11
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Default Re: The New Build... 1999 Fleet Cart

Looking good. Keep us posted with those detailed pics What type of 2g cable is that?
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Unread 09-15-2008, 07:28 AM   #12
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Default Re: The New Build... 1999 Fleet Cart

To be honest - I'm not sure. A friend of mine runs an installation company that specializes in car audio - show cars and competition stuff - very high end. I purchase it from him - it's freaking EXPENSIVE... even at wholesale!

I've been using it for several years with 100% success.
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Unread 09-17-2008, 06:50 AM   #13
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Default Re: The New Build... 1999 Fleet Cart

I'm starting to recieve the parts and pieces that I need to finish this cart... I have a very anxious customer that has "the fever."

Last night I started the installation of the lights, brake switch, turn signal kit. I have to say - this kit was REALLY easy.

First step was to secure the turn signal device (sorry for the crappy picture) and run the wiring.


Once the signal is secure, run the wire down the steering column and cover with the plastic piece that snaps on. Next, I took a small hole saw and drilled a big enough hole in the driver side cup holder area to run the harness plug through. Here you can see the plug coming through into the cup holder cavity.


While I was at it I changed out the key switch, plate, and added a 36volt meter. Since I am not using the supplied push pull switch - I cut it off and wired the headlight into the 3 position key switch.


Next step was to mount the fuse bus on the rear fender well. EZPZ.


Once the bus was mounted I started to run the wires for the brake lights with zip ties across the top of the frame.


Next - I started to run the wires forward to the front of the cart - this includes the brake switch. It's a plunger type of switch - where the depressed position is colsed. Once you move the brake pedal - it opens and activates the lights. It's on a timer - so once you press the parking brake, the brakes only stay on for 30 seconds or so. This will be a moot point though - because I'm running the fuse bus off of a relay that is connected to the key switch. Basically - once you turn the key off - both the 36volt and the 12 volt systems shut down.

Brake switch...


It mounts just above the pedal assembly arm...


Mounted...


Finally - I finished running the rest of the harness to the front of the cart where it will tie into the key switch and the headlights.



That's all I got done for last night on that cart. Tonight I hope to get the body panels templated and cut out to recieve the headlights and tail lights.
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Unread 09-17-2008, 07:49 AM   #14
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Default Re: The New Build... 1999 Fleet Cart

Very nice work!

Can't wait to see the finished product.
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Unread 09-17-2008, 09:31 PM   #15
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Default Re: The New Build... 1999 Fleet Cart

Here is a quick "how to" on cutting the body and installing the lights...



First - cut out the template for the lights and tape it into place....

Trace it out with a marker



It's okay to make the first cut small. I used a jig saw and a fine tooth blade. The issue is that the body melts back together when you make the cut. I trimmed any spots with a small dremel and a flat file until the light housing fit the way it should.

Once its in place you can drill the holes and mount the light.




I will likely change out the self tapping screws provided with some bolts and nuts along with washer. It just seems like the lights will stay in place better.
Basically the same process.





Next I'll remove all of the lights and get the body ready to go to paint. Hopefully by this weekend I will be finished wiring up the relay for the 12 volt accessories, running additional wires, and pulling the input shaft out of the rear so I can replace the O-ring that is causing the leak. Hopefully the bearings arent shot as well. The motor should be here in a week or so... the wheels, tires, dash, top, and rear seat should be here too. Once I get the rear seat I can get that ready for paint, upholstery, etc... there is still a bunch to do on this thing.
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Unread 09-18-2008, 10:07 AM   #16
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Default Re: The New Build... 1999 Fleet Cart

Lookin good........ Keep the photos coming............
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Unread 09-19-2008, 09:46 AM   #17
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Default Re: The New Build... 1999 Fleet Cart

Looks good so far. I will be doing this to mine soon, hopefully, lol
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Unread 09-19-2008, 07:57 PM   #18
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Default Re: The New Build... 1999 Fleet Cart

Lookin' Good!
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Unread 09-23-2008, 02:33 PM   #19
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Default Re: The New Build... 1999 Fleet Cart

Sorry - no new pictures on this update..... (The soon to be owner is getting nosey and trying to sneak a peek)

Here is where we are...

- The headlight, signal, brakelights are installed.
- The body has been cut for the lights.
- The cart is wired - including the 12 volt accessories which are now
controlled with the key switch via 36 volt relay.

- Wheels and tires are here - 12" low profiles that are so sexy they make me sick with jealousy - fact is... there is an outstanding chance that I will be selling my ITP's and putting these on.

- Dash is here along with the chrome, rear seat, new window, rear view mirror, and seat belts. The dash is slick - wood grain doors and a leather look...

- The body has been dropped off for paint and should be ready by this weekend. Deep Midnight Metallic Blue.....

- The motor should be shipping this week - then I can unbolt the old one, pull the input shaft out and repair the gaskets that are causing the leak. Re-fill the rear end and bolt up the new motor....

- I need to go get the stereo and speakers still - which I will do this week.

- Looks like I should have the front and rear seats re-covered by this weekend as well - and I'm toying with the idea of pinstriping it too...

- One of these days I will get the 80" top for it too...

I will keep taking pictures as I go forward - and probably post the results towards delivery day - which is scheduled for 1 week from this upcoming saturday.
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Unread 09-24-2008, 09:09 PM   #20
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Default Re: The New Build... 1999 Fleet Cart

Alright - it appears as though no pics = no posts.....

There is only so much I can do on this one at a time.... Like I said - I have the dash and pretty much everything that I need to complete the cart. This weekend I will get the seats done as well....

Today's exercise was to get the stereo shored up.... it's always nerve racking to cut through the dash... much less the brand new dash cover - which is SWEET by the way... leather look with wood...

Anyway... first step was to take the chassis of the deck and trace it out on the dash cover. The Dremel is your friend here.... Then, very carefully cut out the hole... flat file is also a good tool. Remember - patience is really the key here for a good fit...


Once you determine that the chassis fits through the new hole - let's start trimming away the ball holder area on the cart... start by cutting the sides, then the trim around the top. Try to leave the lower lip to support the stereo..


Looking at it from the back....


Once cut and trimmed away - continue to test fit until you're happy....


Now - let's look at the speakers. I find that 5-1/4" fit the best - and every time I do an install - I default back to what I know works best.... under the cup holders. Keep in mind - its much easier to do this with the front body panel off - not impossible though with it stil on....

Template out the holes....


Cut them out... again - its okay to start small... then simply put the speakers into the holes and screw them in... this is a view from the top (inside of the cup holder)


This is the view from under the cup holder - no, I'm not limber...


Final step is to wire it up - but that's easy.... I'll probably do that tomorrow.

I also dropped in some "cabin lights" mounted on the floor of the cart just below the glove compartment - these will be operated by accessory swithc...


I'll try to post again tomorrow.
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