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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 12-15-2015, 11:39 PM   #1
chewy65
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Join Date: Jan 2015
Location: Bend, OR
Posts: 54
Default 48 Volt Lithium Project

After building 2 carts for my parents is was finally time to build one for myself.
I found a good 2007 EZ-GO TXT 36V without a controller, knowing I was not going to need the controller anyway. Here are some pictures of how the cart started when I got it home.
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Old 12-15-2015, 11:55 PM   #2
chewy65
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E-Z-GO
 
Join Date: Jan 2015
Location: Bend, OR
Posts: 54
Default Re: 48 Volt Lithium Project

the cart was then torn down to get cleaned up and find out all what I needed to do. I had to get the body cleaned as well as it was not going to remain that color. I had no idea what the wiring was like when I bought it and thankfully it mostly all appeared to be there.
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Old 12-16-2015, 12:10 AM   #3
chewy65
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Default Re: 48 Volt Lithium Project

Since I knew I wanted the cart to be converted to 48V and I needed a controller, I thought I might as well get a good motor to go with it. I found what I was looking for from Scotty B. and with his advice purchased what I needed. I bought the D&D high torque motor and the Alltrax 500 Amp controller and 400 Amp solenoid.
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Old 12-16-2015, 12:22 AM   #4
chewy65
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Default Re: 48 Volt Lithium Project

The next step was to figure the power source. I have seen Lithium batteries in some of the equipment I work on for my job and have always been impressed with the power and technology of it. So I contacted a friend that is getting into the Lithium battery industry, DES (Dynamic Energy Solutions) and he had a couple of 48 volt battery packs that were perfect for what I wanted, so I put in an order for 2 packs and planned on running them in a parallel configuration. With that though, the stock battery tray was not going to work any more. I removed the tray and modified it work with the packs that I was going to receive and I also decided that I wanted the charger and everything to be mounted on-board the cart, so we could just plug it to charge it with a regular extension cord
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Old 12-16-2015, 12:32 AM   #5
chewy65
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Default Re: 48 Volt Lithium Project

I then ordered a 4 inch lift kit, got some 21 inch tired, and had the body painted black. I also purchased all new suspension parts since the cart was 8 years old and was starting to have a little sag in the springs and shocks. I figured while it was all apart it would be easier to do it now then later when the cart was assembled. I also installed the motor.
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Old 12-16-2015, 12:41 AM   #6
chewy65
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Default Re: 48 Volt Lithium Project

The next part was to tackle the wiring. I had some idea what condition it was in, but since I was pretty much changing the whole system, it took a while to get it all labeled so I could install the parts. I also added a 48V to 12V power converter, digital voltage display and cover plate from Scotty B. This is a very nice set-up and fits perfectly.
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Old 12-16-2015, 12:58 AM   #7
chewy65
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Default Re: 48 Volt Lithium Project

I received the batteries and charger and proceeded to get them installed. They weigh about 80 pounds a piece so both battery packs and the charger ended up being about half the weight of a lead acid battery setup. It also allows for room behind the battery packs to mount the charger, and some terminal blocks for the wires and the fuse. All the wiring was up sized to 2 guage.
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Old 12-16-2015, 01:13 AM   #8
chewy65
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Default Re: 48 Volt Lithium Project

I finally got the cart to where it is today, put some new covers on the seats, new top, steering wheel, I also did not use any rivets in putting this back together. I was able to use 1/4-20 bolt and screws in the place of the rivet so if I need to take anything apart it will be easier. The cart is quick and fast, I am so pleased with the lithium batteries with the motor and controller setup. I have a slight hill next to my house and had it going 23 MPH up the hill and 28 MPH down the hill. The way it climbs hills is effortless and the does not slow down much. The way the lithium delivers the power it has very little slow down under load as well. I have not had much time on it yet as it started snowing shortly after I completed it.

The next steps are to first install a set of disc brakes since it does not stop fast enough for me knowing that my wife and daughter will also be driving it. I also have had a request from the family for a rear flip over seat for the daughters friends to ride on. I also plan on installing a limited slip differential. I know it will be a forever project, but it sure is fun to play with too.

I would like to thank RMT Equipment for the cart and many of the EZ-GO parts, Scotty B. at Carts Unlimited for the technical help, advice and parts, D&D motor for some technical help as well, and DES Lithium Batteries for the awesome packs. More to come hopefully.

And yes I am an OSU Beavers fan/alum hence the stickers.
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Old 12-16-2015, 07:49 AM   #9
mutant
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Default Re: 48 Volt Lithium Project

very nice!very similar to what i would like to do...
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Old 12-16-2015, 08:02 AM   #10
03psd73
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Default Re: 48 Volt Lithium Project

Great looking cart.
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