The New Build... 1999 Fleet Cart

Blue Chip

I have a customer that mentioned that he wanted something that he could use around his neighborhood - it's a good place for carts. I've been keeping my eyes open for the right deal to use as a donor cart. He gave me the go ahead for the build with his criteria... mid 20's mph, 4 seat, wheels, tires, headlights, brake lights, turn signals, custom color, etc... basically another version of my personal cart.

For the time being we will keep it at mid 20's mph.... I explained that 30+ is a bit of a stretch and it cost minimally an extra $1K to get there. I'll be getting a new motor that is basically spec built for this particular application - and I'll have it wound to handle higher voltage should the new owner decide to "up" the speed requirements. I spent time speaking with Chuck at EMP - every time I talk to him I'm floored with how much he knows....

Well.... Here it is. A 1999 EZGO Fleet model 36volt. This is as stock as it gets - but it is outstanding condition.





First steps is to tear this thing down to the frame, get the body ready for paint, and give better access to the rest of the hardware.

Top comes off...


Front body panel


Rear panel



Next step is to pressure wash the frame and replace all of the batteries. I'll need to custom make some 2ga. battery cables to handle the draw from the new motor and to help the stock 36 volt system retain some lower end torque.

We need to decide on a color. He trusts me to get the right wheel and tire combination - I'm thinking some sweet 10" rims in polished aluminum with low profile tires. We're not going to lift this one right off. I'll also have to start looking to source a rear seat, an 80" top to cover the rear passengers, head lights, tail lights, signals, stereo, speakers, and all of the trim work. He wants to see a bunch of chrome on this thing so it stands out. Also will need to rebulit the rear diff, replace the leafs with hd 4 spring packs, and maybe a couple of the shocks.

BGW

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GXTsandman

Cool project. Must be fun to play on somebody else's dime. I look forward to seeing the progress.

scottyb

What did we have to give for the cherry donor cart?

Blue Chip

I'm almost ashamed to admit..... $500.

scottyb

Blue Chip

Batteries and wiring removed, pressure washed.

Next steps will be to take care of the surface rust in the battery tray - even though there is practically none... this thing is in better shape than most 2 year old carts.

I'll get the new batteries on order and custom make some 2ga. cables for it. I've also got to get the new speed motor on order - that's a 3 week turn around from EMP.

While the cart is stripped down like this I'll get the stereo wired up and all of the accessory wiring run for the 12 volt power, lights, battery meters, etc....

Still deciding on a color. I'll look for rims and tires over the next week or so. Also need to source a new rear seat for this thing.

scottyb

Looking Good!

Blue Chip

Well - I took a few days off to travel to South Florida.

I managed to get some work done today on this thing. I custom cut some 2ga. wires and soldered up some lugs. Took the time to replace every wire on this thing... If memory serves there were 7 or 8 of the old that got changed out to the 2ga. I'll do the battery cables when I pick up the new ones.

I also took the time to surface prep any rust in the battery tray, prime, and paint. There really wasn't much there - but I figured now would be the time to do it.

Last step was to replace the rear leafs with HD ones to help with the weight of the back seat.

This week coming up I'll be placing a HUGE order for parts. That will include a rear seat, wheels and tires, chrome and diamond plate stuff, dash, etc...

If any of the site vendors want to talk about this - I'm listening! Shoot me a PM. I'd rather give the first shot to the sponsors here.

Blue Chip

Quick update -

Buyer provided the second cash draw...

Currently on order are a new set of Trojan T105's that I will pick up locally on Friday.

I will also know if an 80" white top and a rear seat are available.

Once I know that - I can place my order through the wholesaler.

Need a new dash, wheels and tires, EMP, chrome, stereo, headlights, tail lights, signal, etc. Hopefully I can source a rear seat locally for a good price because shipping would be painful - I'd be looking at close to $400 for a rear seat by the time all was said and done.

There is a sweet deal for 12" rims and tires right now - buy a certain number of sets and shipping is free - that would put a set of wheels / tires right around the low 4's. I have one other cart behind this one - but I may take the chance on pulling in an inventory.

Blue Chip

Just a quick update - This should be a week of progress... all of the parts are coming in (or should be). Right now the batteries are in and the 2ga cables are done. I saw a conversation in another thread about putting the lug ends on - and crimping versus soldering. I use solder and have great success with it - here is a shot of a finished end for those that have been curious...



Anyway - this week projects are:

Install headlight/brakelight/turn signal kit along with brake microswitches.
This will mean cutting out the body...

Wire up the "house" accessory panel for all of the goodies.

Wire up a relay - that way all accessories will shut off at the key switch.

Re-cover the cushions.

Install rear seat.

I will take as many pictures of the process as I can.