proper welding prep.

[fredfarkle]

Hi,
I am going to have to replace the battery rack shortly. I wanted to know how to prepare electrically. Do I remove controller?
It is a 1993 ezgo marathon, with the series motor.
I want to ensure it will run when the welding is complete.
thanks
fredfarkle

[gravelydude]

Fred,

I would definitely remove the controller.

Jack

[cgtech]

I would just disconnect the batteries. Never failed me before.

[Jeffreynmandy]

I love this site. I was about to ask the same question.

I want to weld a small bracket onto the front axle. I know I'd unhook the batteries.

I'm worried about the controller as well. If I put the ground on the front axle and weld the tab. Could any kind of current travel through the axle, frame, and then to the motor and controller.

I know it's unlikely to hurt anything but I want to be extra careful with a $600 controller.

[cgtech]

I feel you are ok. If you hook up anywhere but the axle, you could weld the kingpins solid (that'd be interresting).

[gravelydude]

I am sure that Cgtech has a lot more experience than I do; and he is probably right. Still, if it was my cart, I would take the time to remove the controller before welding. Why take a chance? Just my opinion.

Jack

[Sergio]

Automakers recommend that before technicians do any welding on vehicles, they should first disconnect the battery of the vehicle and remove (or pull back) any wiring harness or electronic components that are within 12 inches of the weld.

Probably related to induced voltages caused by the welding arcs.

[Jeffreynmandy]

Well I went ahead and tried it. I disconnected the positive and the negative. I then turned the reverse switch to let it drain. It took severeral minutes.


I hooked the ground only a few inches from the weld area. It's been so long since I've welded, I let my BIL weld it. It was only two or three inches of weld total.


It worked out and every thing runs. This was down on the front axle, I can't say if it would work for anyone else, but it went ok for me.

[DaveTM]

Originally Posted by cgtech

I feel you are ok. If you hook up anywhere but the axle, you could weld the kingpins solid (that'd be interresting).

I don't weld.....but I do understand the concepts of why "welders" recommend to do this "stuff." But when I read this about the possibility of the kingpins just kind of seizing together.....I found in LOL funny. Not that I would wish it on anyone.....but if theres a chance of it happening......it would likely happen to me. Funny.....but in a sick sort of way.