Billy Jack 1996 EZGO Medalist Project

[yurtle]

I used paint on bed liner for my battery trays, after cleaning them thoroughly. My thought is the batteries may slide around, and bed liner is made for use in a pickup truck bed, where things are often slid in and out, and may slide around while driving.

[TechBill]

Finally I had some time to get back on this project.

I ordered the charging plug and receptacle off Ebay which was cheaper than ordering it from anywhere else.

Tonight, I clipped of the 115v plug off the charger and installed the proper charging plug on it.

[TechBill]

The 115v plug on the charger was missing a ground pin and the wire near it was frayed. I decided to use the plug which I took off from the charging wire and use it to replace the bad 115v plug on the charger.

[TechBill]

The previous owner cut out the wiring from the charging receptacle and the receptacle itself seem to be cracking so I ordered a new one to restore the existing one.

Added a 10 gauge solid wires to the charging receptacle.

[Bull203]

I would by far recommend POR15, used it on two CJ7 frames and a golf cart frame. it works great

[orangeman6]

Originally Posted by TechBill

The previous owner cut out the wiring from the charging receptacle and the receptacle itself seem to be cracking so I ordered a new one to restore the existing one.

Added a 10 gauge solid wires to the charging receptacle.

Bill, I'm pretty sure you'd be better off not using solid wire on the cart. There's a lot of vibration with the golf cart bouncing down the road, and I think it can fatigue solid wire. Someone correct me if I'm wrong, but I believe solid wire should only be used in stationary applications.

[TechBill]

Originally Posted by orangeman6

Bill, I'm pretty sure you'd be better off not using solid wire on the cart. There's a lot of vibration with the golf cart bouncing down the road, and I think it can fatigue solid wire. Someone correct me if I'm wrong, but I believe solid wire should only be used in stationary applications.

You are correct, I don't know why I thinking solid when I brought this wire after I asked about it in another post.

I must had a brain fart when I went got the wires. I will go back and get the stranded one instead.

Thank you

[TechBill]

After the recent brain fart of buying solid wire for the charging receptacle, I went back to the store and got stranded wire this time. The old charging receptacle had a solid wire but then again it was probably a mistake done from the previous owner which might had me thinking "go solid" at the store.

Replaced the wires with stranded one.

Removed the "redneck charging receptacle"

Removed the old charging receptacle and put in the new charging receptacle and ran the wire around to the front of the cart to the battery terminal.

It is charging now with the new plug and receptacle. The voltage is reading about 41 volts while charging. Not sure what he peak voltage is on this charger but I assume anything above 36v is good.

I have a question about my automatic charger but I will post it in a new thread.

[TechBill]

I have put this project off for so long time since I discovered the frame was rusted through too. But I finally gotten around to buying a donor frame for it which seem to have only surface rust so I am getting ready to go back on this project again.

I am thinking I should do more than just replace the frame on it. Maybe put in modern day controller for it and give it a lift too.

Any suggestion what I should upgrade on this cart? I want to keep the same motor for now however I am open to suggestion on what controller or other upgrade to get for it.

Thanks

[TechBill]

Look like Alltrax is the way to go for controller ....

One website mentioned that any carts build on or before 1995 uses a series motor but Iam sure my serial number show that my cart is build in 1996 however I am also sure it got a series motor too.