Marathon rebuild

[Newbuggyboy]

Originally Posted by Phil_Billy

I know upgrades can be expensive. I have been buying and sitting on parts for the last year for my project. I picked up a really clean "91 Marathon few weeks ago for under $300 and started adding the stock piled parts.

I converted it to 48v and I installed a 1206-5201 48v TXT Freedom controller unlocked and a 5 hp Advance motor. only lifted mine 2 inches, still have the 8 inch steel rim'd tires. the ITS was the biggest challenge and I used the original F+R modified to use the micro switches instead of a toggle switch. also swapped out the differential carrier with a limited slip diff from an RXV.

the batteries wiped out my cash for now. I am saving money now for some 10" aluminum rims with tires. cart currently runs at 19-20 mph. I'm gonna post some pictures of it, once I offload them from my phone to laptop.

I'd love to see the pictures. What did u spend on the controller upgrade project?

[Phil_Billy]

right at the moment I have spent around $1000. $300 on the Marathon and another $700 for 6 - 8v batteries.

some years ago I traded out an old 48v Club Car DS for a wrecked 48v TXT Freedom minus the batteries. the batteries were not part of the trade, as the DS had no batteries and they needed the cart for daily transportation. I live in a golf cart community with 17,000+ registered golf carts.

I will try to post some pictures tonight, right now I am on a lunch break.

[Phil_Billy]

Originally Posted by Newbuggyboy

I'd love to see the pictures. What did u spend on the controller upgrade project?

here some pictures

[Newbuggyboy]

Originally Posted by Phil_Billy

here some pictures

Your cart looks sweet.

My front is 1/2 lifted 4". No that doesn't mean it lifted 2". It means I have to attach the shocks.

Originally I thought I could put the shock extender up top. When I tried the lower end of the shock was interfered by the 4" pedestal. Darn, I was going to replace the front shield with clear plexiglass. I was going for that "visible" suspension look. So my cool shock boots and lift would show off. When I was young they had a "visible" human prop for science/health clases.

[Phil_Billy]

Originally Posted by Newbuggyboy

Your cart looks sweet.

My front is 1/2 lifted 4". No that doesn't mean it lifted 2". It means I have to attach the shocks.

Originally I thought I could put the shock extender up top. When I tried the lower end of the shock was interfered by the 4" pedestal. Darn, I was going to replace the front shield with clear plexiglass. I was going for that "visible" suspension look. So my cool shock boots and lift would show off. When I was young they had a "visible" human prop for science/health clases.

thanks.

maybe you can fab something like the shock mount plate from an RVX. then attach your shock to the top of the lift kit and above the spring. you won't need to use the extender and you can cut the existing shock mount off the axle.

my son stopped by, so I snapped a few of my first Marathon project.

[Newbuggyboy]

Originally Posted by Phil_Billy

thanks.

maybe you can fab something like the shock mount plate from an RVX. then attach your shock to the top of the lift kit and above the spring. you won't need to use the extender and you can cut the existing shock mount off the axle.

my son stopped by, so I snapped a few of my first Marathon project.

Very cool carts you have.

I probably won't fab.

So "is it safe" to call you Marathon Man? Lol

[Phil_Billy]

Originally Posted by Newbuggyboy

Very cool carts you have.

I probably won't fab.

So "is it safe" to call you Marathon Man? Lol

I do like my Marathon's. I've been working on another Marathon before I picked up the red cart. I added 8" of length to the frame and have been slowly getting it done. I put off for now and will pick up once its a bit cooler outside.

[Newbuggyboy]

I finished the shocks yesterday. And now the lift kit is complete. I was waiting on tie rod boots before working on steering rack. Those came today. So looks like a weekend project.

[Newbuggyboy]

So I decided I better do that motor test b 4 I go to deep with $.

You may want to move ahead in the video to @30 if your impatient.

And yes "Houston we have lift off!"

Woot! Woot!

https://drive.google.com/file/d/1-s7...w?usp=drivesdk

Note that pictured battery sparked but didn't turn the wheels. I jumped it from the car.

[Newbuggyboy]

So I did have an issue during the motor test. I could not remove the wires from the motor leads. So I took off the other ends to make it work. I would like to replace these wires.

The problem is the leads seem to be a double thread bolt. One side goes into motor. Then there is a nut. Then another thread to put the wire on. Followed by another nut. Does anyone know how these work? Can you explain how to remove them? I tried a wrench and a socket. But the the two nuts were different sizes. The outermost was 1/2". The inner was larger than 1/2", but the 17/32" or 9"/16" didn't fit. Maybe just that one was buggered.

The photo is not my motor but shows the same type of lead.