1994 Medalist Reborn Build

[TXST8tj]

In December of 2021, I picked up a 1994 EzGo Medalist for $100 on Marketplace. I basically bought it because the frame was in great shape. The plan was to rebuild a cart from scratch, so it was no issue buying something just to throw away a bunch of parts if needed.

The roof was dirty, but apparently pretty new. The wheels and tires were also fairly new. The battery tray was rotten. No front lower seat. A couple loose wires left from the wiring harness. Basically all electrical was toast.

The plan?....tear it all the way down to the frame. Clean it, paint it, and build back up from there.

The last two pictures are of the first cart I rebuilt several years ago.

Stay tuned as I get this thread up to date.

[TXST8tj]

A few months ago, I pulled the cart back around to the front and started the teardown process. I pressure washed it along the way because there was caked on mud every place I looked.

Most of the dismantle went smooth. The forward roof support bolts were all seized. I ended up cutting them flush and drilling them out. Rather than re-tapping, I will likely just use through bolts and nuts.

Once I started pulling panels and parts off, I realized I would not be satisfied unless I took it all the way down. In the process, I found many parts that needed to be replaced from being just worn out or seized with rust.

[TXST8tj]

Once completely stripped down, I took a wire wheel to the frame and knocked down any loose paint and surface rust.

I laid down a couple coats of Rustoleum primer, followed by a couple coats of Rustoleum enamel black paint.

Once that was back in the messy garage on stands, I did the same procedure on the individual metal parts I removed.

First up to get the cart back together was getting the suspension under it.
5"-6" lift kit, HD front springs, HD rear springs, new shoulder bots, new bushings, new shocks.

$390 in suspension parts
$120 or so in paint

[TXST8tj]

Before putting the axle back under the cart, I opened up the diff and inspected the gears. Everything looked to be in good shape, so I drained it and added fresh fluid to it.

Once the axle was back under the rear end, I pulled the brakes and replaced them with full new kits.
I also replaced the brake lines, the compensator (spring), the pedal spring, bushings, and the pads on the pedal. So in all, I have a fully new brake system.

$200 in axle and brakes parts

[TXST8tj]

With the rear back on the tires, I went back to the front and freshened everything up there. I cleaned the stock spindle hardware and reinstalled. I picked up a new bearing kit for the front hubs and reinstalled those. I also replaced the tie rods.

You can also see here the Monroe shocks in the front. Same ones are in the rear. I used these on our last cart and they worked well.

$125 spent in front end parts

[TXST8tj]

Back on all four tires. Steering rack re-installed, along with the steering column.

When disassembling the steering column, the bushing fell apart, so a new one and back in business. Also installed the new steering wheel.

New battery tray is also back in, and I am starting to get the rest of the body panels riveted in place.

After putting the new pads on the brake pedal, it really made the throttle pedal look its age. I ordered a new one and will install soon. Interesting how I could only find one anywhere. It came with rivets, but no holes....until I drill them. So waiting to put the floor panel back in until I replace the pad.

$63 for steering wheel, adapter, and bushing
$78 for battery tray

[TXST8tj]

The next focus is getting the electrical parts installed, and a couple more items ordered.

Next round of parts coming up:
motor controller
wiring harness
f/r switch
solenoid

Next to order is the new motor

[Capt. Lenny]

Nice project! Looks great so far. Keep up the good work! Can’t wait to see the finished product.

[TheNewGuy]

Nice clean work! Lookin good so far.

[Cartmaster]

Best upgrade for this cart would be fitting a TXT body and cowl, takes it to another level!

Maybe even an aftermarket TXT body kit.

Looking good already though.