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Old 09-09-2021, 01:13 PM   #1
Micbad
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E-Z-GO
 
Join Date: Jul 2021
Location: DFW
Posts: 41
Default 1999 EZGO Project

Hello All,

I am starting this thread to chronical the journey of building this cart so it will perhaps help others.

What started as my wife saying hey you should build us a nice golf cart has turned into something a little more substantial. My wife knows my engineering self well so I suspect she outsmarted me (again) and knew this would keep me busy over engineering / building a simple golf cart. As usual, she was right.

This first post is just background and i will add to this thread as I complete steps.

We wanted a larger cart for all our activities. The neighborhood we live in is largely flat but has a lot of off road trails and streams to traverse if you are so inclined.

I have never built a golf cart or even owned one before this project. Some might say wow why would you undertake this - well those that would say that don't know me - lol! I have built hotrods and airplanes for years (yes aircraft) so I thought a golf cart was inside my wheelhouse.

Please feel free to chime in if you have advice or cool ideas for me to think about or consider - I will enjoy community ideas, support and of course questions. For all the others who come after me they will get what I got from reading others who have done this as well - a wealth of knowledge and learning.

Thanks and hopefully you subscribe to the thread for updates.

Mike
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Old 09-09-2021, 01:19 PM   #2
Micbad
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E-Z-GO
 
Join Date: Jul 2021
Location: DFW
Posts: 41
Default Re: 1999 EZGO Project

Donor cart acquired.

1999 EZGO DCS for $300

I probably over paid for it but lesson learned. Basically everything inside the cart was scavenged. It had little to no wiring left, motor and controller gone and the left frame rail was rusted through (see pictures).

Mike
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Old 09-09-2021, 01:27 PM   #3
Micbad
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E-Z-GO
 
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Default Re: 1999 EZGO Project

Now to clean up the cart and see what I am dealing with.

As I mentioned, basically everything was pretty well rusted, missing or well ugly.

Here are some shots of it cleaned up.

M.
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Old 09-09-2021, 01:40 PM   #4
Micbad
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E-Z-GO
 
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Posts: 41
Default Re: 1999 EZGO Project

Ok now she’s naked in these photos…

Again finding the rust and just how many bolts were rusted through. I drilled out what seemed like a million rivets.

No surprise category…
- Brakes all rusted together and worn completely out
- driver side frame rail rusted really bad
- all suspension components well worn
- battery tray rusted through
- steering bushings all worn
- seats plastics all worn out

Pleasant Surprises…
- rear end in good shape but needed axle bearings and seals

M.
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Old 09-09-2021, 01:46 PM   #5
Micbad
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E-Z-GO
 
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Location: DFW
Posts: 41
Default Re: 1999 EZGO Project

Stretching the cart so first order of business was to cut the frame and fab some extensions for it, fix the frame rail, sand blast and powder coat.

Some good photos of the color…. Illusion purple

Fun!
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Old 09-09-2021, 02:01 PM   #6
Micbad
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Posts: 41
Default Re: 1999 EZGO Project

Rebuilding rearend…

- replaced axle bearings and seals
- all other bearings and shafts in good working order so didn’t replace.
- painted axle and housing versus powder coat so I didn’t need to strip it for the powder coater (seemed over kill).

Also - lesson learned - ring gear torque specs are NOT all the same. I had a manual from a newer ezgo rearend - they call for about 60 ft/ pounds - well let’s just say the older rearends are not 60 but rather 40 ft / pounds. That’s of course is a range and those torque figures are the mid point.

I got to replace all the ring gear nuts and bolts for making the assumption that ring gear spec is the same as the older rear ends.

Beware - many torque specs vary slightly.
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Old 09-09-2021, 03:39 PM   #7
trig123
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Default Re: 1999 EZGO Project

Very nice.
I will watch as you continue to bring this old DCS back to life.
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Old 09-10-2021, 12:17 AM   #8
Cartmaster
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Location: United Kingdom
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Default Re: 1999 EZGO Project

I am with you on this one Trig. Its gonna be an interesting build. Takes me back to when I had my shop doing bespoke custom builds. I had to fabricate just about everything as aftermarket stuff was not readily available in those days!
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Old 09-10-2021, 07:20 AM   #9
TheNewGuy
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Default Re: 1999 EZGO Project

Nice work so far!

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Old 09-10-2021, 10:30 PM   #10
Micbad
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E-Z-GO
 
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Location: DFW
Posts: 41
Default Re: 1999 EZGO Project

A deeper dive is in order on the modified battery tray. As expected, the stock tray had basically dissolved into red dust. My guess is the stock tray started rusting before it left the showroom floor. Fortunately, there are several replacement options so I decided not to start from scratch but in hindsight I probably should have made my own. Regardless, I bought a steel one, cut the battery loops off and welded a flat steel plate to the top. As you can see I powder coated it.

The flat steel plate was done in anticipation of installing a single lithium battery system in the cart.

I decided on the monster itself for this large, heavy and lifted cart. This tray will support an Extreme Team 72V 200Ah lithium box. That battery will consume the entire tray and weights 276 pounds. It should arrive in October sometime.

This battery is the largest most powerful battery (off the shelf) I could find that will “fit” in the space given. It’s going to be tight and I’m anxious to see how I’ll mount it. Extreme team suggested straps but that’s not really my style so once I have it I’ll fab something a little more custom.

Until next time…
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