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Old 02-17-2011, 03:36 PM   #1
tplasek
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Default New to carts - My 01 build

I'm new to carts, but I recently brought home this 01 EZ-Go. After a valve adjustment the compression went from 120 to 180 psi in both cylinders. With good compression, my plan is to keep the existing motor and rebuild the rest of the cart with an orange and black Harley Davidson theme. This is a picture of it the day day I brought it home.
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Old 02-17-2011, 03:43 PM   #2
tplasek
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Default Re: New to carts - My 01 build

After driving it around a few day, I decided it was time to tear it down and get started with the build. When I disassembled the existing rear seat, I found several major braces were missing and the seat was actually just bolted to the plastic body. I decided if I had to cut and weld parts to this old thin gauge seat frame, I may as well make a new one. Below are pictures of the old frame and my new flip seat frame. My new frame is all 3/16 steel and has a tow hitch for pulling back all the battery powered buggies that run out of charge! In the pictures below, I haven't installed the diamond plate sheet metal yet. After I got my seat frame mocked up, I tore it the rest of the way down and pressure washed all the grime that was under the plastic body.
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File Type: jpg 5443480616_eb387ccfd2_z.jpg (56.1 KB, 34 views)
File Type: jpg 5382833014_6829e751b6_z.jpg (67.7 KB, 39 views)
File Type: jpg 5382230569_1257d3cc0e_z.jpg (60.3 KB, 38 views)
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Old 02-17-2011, 03:48 PM   #3
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Default Re: New to carts - My 01 build

So far I have purchased:
5" All sport lift kit
Some aluminum wheels from Summit Racing. They had these for $55 each plus $10 shipping. I couldn't pass them up.
A pair or Kicker marine speakers
A marine amp
I had my clutch modified by Carts Parts Plus plus converted to the 28 degree helix
All new belts
Led taillights for brake lights
Under body LED lights
HD rear springs
and a bunch of diamond plate accessories
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File Type: jpg 5442878943_bddce56c07_z.jpg (51.7 KB, 20 views)
File Type: jpg 5443481914_733b0da0ec_z.jpg (60.3 KB, 23 views)
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Old 02-17-2011, 03:54 PM   #4
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Default Re: New to carts - My 01 build

Last weekend I was able to get the body sanded and primed. I learned a bit about the plastic body on EZ GO's. It is made from TEO plastic which is very similar to the TPO plastic bumpers on most cars. My understanding was it is almost impossible to sand TEO plastic with sand paper and red scratch pads (like Brillo pads) were recommended. I used these for about two hours and wasn't satisfied with the result. I pulled out some 400 grit paper and was much happier with the result. But, when it came time to scuff the inside and undersides of the plastic, the sand paper just mad a big mess and I had to use the scratch pads. This is when I found out my EZ-GO body (don't know if they are all like this) has green paint, on top of black primer, on top of green plastic. All the outside panels already had paint on them which is why the scratch pads didn't work.

I used Bullydog adhesion promoter and PPG black epoxy primer. I primed both sides of the body. I will leave the undersides in black primer and plan to paint the topside with some sort of orange and black Harley Davidson theme this weekend.
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File Type: jpg 5442881189_9461ae7dde_z.jpg (57.3 KB, 22 views)
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Old 02-17-2011, 03:55 PM   #5
mikeevans860
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Default Re: New to carts - My 01 build

Very nice and what a good deal on those rims
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Old 02-20-2011, 08:59 PM   #6
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Default Re: New to carts - My 01 build

I got the body partially painted this weekend. The Harley logo stencil for the front clip accidentally stuck before I was ready for it to. I couldn't pull it up to straighten it without destroying the stencil. I decided not to paint the logo on the front clip, and wait until I can get a new stencil. Here is a picture of how the body turned out. I am very happy how it turned out.

[IMG] DSC_1977 by TimPlasek, on Flickr[/IMG]
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Old 02-20-2011, 10:06 PM   #7
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Default Re: New to carts - My 01 build

nice paint job! hope to see some more pics.
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Old 02-21-2011, 09:41 AM   #8
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Default Re: New to carts - My 01 build

Great lookin' paint. Looks like you'll have a show winner when you get finished. Keep the pic's coming!
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Old 02-21-2011, 09:52 AM   #9
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Default Re: New to carts - My 01 build

Thanks for the paint compliments! Photography is a hobby of mine, so I'll make sure to take plenty of pictures. I'm in graduate school so I can only work on the cart and make updates on the weekends. So far this is three weekends of work.
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Old 05-11-2011, 05:08 PM   #10
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Default Re: New to carts - My 01 build

So wheres the rest of the pics of this build? I like it!
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