1981 EZGO Marathon Rebuild Project

[j_man_21050]

Hey all! First time cart owner here. Caught the golf cart bug after spending some time at a camp ground with a golf cart.

Goal - complete frame up restoration
Budget - $3,000 (including batteries and new/rebuilt motor)
Skill level - competent with mechanical and electrical wiring
Timeframe - work in progress

I do not want to keep it stock. I want to remove ALL of the old wiring and replace everything except for the motor right now. Not even sure the motor is functional as the cart did not have batteries when I purchased it and have no way of testing without batteries.

Condition - frame is solid. Body panels have some rust. The floor pan may need replaced as well as the piece under the seat behind your legs and battery compartment. Battery compartment framing needs replaced/rewelded. Suspension is intact and functioning as it should. It looks like a lift was installed in the rear but not the front for some reason.

This is a project cart that will get a tear down to the frame and put back together with a lift kit, new electrics (including motor at some point), rims/tires, seats, etc... Body is in fairly decent shape and will be restored to as original condition as possible. I want an old body with new guts!

What does everyone recommend as far as new electrical components?

My budget (including batteries) is about $3,000. Mechanical drive train is intact and functional and will remain original except for a lift kit, new brakes, and rims/tires. The paid $300 for the cart.

Wish I could post pics without posting them to a third party site first.

[kernal]

First thing: how is the motor mounted? perpendicular or parallel to the transaxle? If perpendicular, no optional motors are available. You will have to rebuild the one that's in it or find a transaxle with parallel motor mount from a newer cart.

Second thing: you can post pictures without a 3rd party. One way to do it here:https://www.buggiesgonewild.com/show...?t=2521&page=8 start at post #78

[j_man_21050]

Here she is in all her "Glory"

[BobBoyce]

Originally Posted by j_man_21050

Here she is in all her "Glory"

I have a parts cart similar to that, except it is a 3 wheeler. The rear part is the same. I removed the motor and gave it to another member here that needed one, he paid the shipping of course. The rear axle is intact, minus the motor, and there may be other parts you could use. You did not mention where you were located...

Bob

[j_man_21050]

Originally Posted by BobBoyce

I have a parts cart similar to that, except it is a 3 wheeler. The rear part is the same. I removed the motor and gave it to another member here that needed one, he paid the shipping of course. The rear axle is intact, minus the motor, and there may be other parts you could use. You did not mention where you were located...

Bob

Hey Bob! I am in Maryland. There are several parts I am missing. The Ezgo Emblem on the front of the cart, rear brake drums, and ignition switch.

I am actually looking for a newer rear end to swap so I can upgrade motors, but am gonna stick with the current rear end until I can find a newer donor cart. I need to speak with someone if it is possible to rebuild my stock motor.

[j_man_21050]

Todays progress on the rebuild

Getting the floor pan out was a huge HASSLE! It was tack welded in place and the tack welds were about 1/4-3/8' wide! Need-less to say my floor pan kind of looks like swiss cheese at the moment!

[j_man_21050]

What is this hole in the bottom of my motor?