My medalist build

[greg9719]

I know how we all love pictures and build threads so I decided to start my own.

First a little bit of history up to this point. The cart is a 94.5 EZ GO Medalist. My Grandfather owns a tree and plant nursery and back around 2000 or so decided to start using golf carts for escorting customers around and pulling the carts we carry plants on. This one was the first one he purchased. A few years ago "the motor and controller blew" apparently and its been sitting on blocks for the past few years. Its been robbed of one of the tie rods and has no batteries. I talked him into letting me have it a few months ago before he passed. I just recently picked it up from the farm about a month ago and started to tear down for a rebuild into a mild off road cart.

I tried to test the motor but didnt have any luck and I havent had any luck finding out how to bench test the controller beings I dont have any batteries.

The first few weeks I didnt accomplish much. Just pulled the roof and a few misc things.

Today I got home from the fire department and decided I was gonna tackle a good portion.

I stripped it down to the frame and have it loaded in the bed of the truck to take down to the car wash to pressure wash (notice the pile of crud that came of during tear down). Im awaiting a shipment of KBS rust coating I ordered Tuesday and will coat the frame in that.

I'll update with more pics as I make progress. Hope ya'll enjoy.


Oh and a side question for anyone that may be able to help. I seperated the case and the end cap on the motor to inspect and my brushes are stuck. They do not move at all. almost as if they burned in the holders. Could replacing my brushes and assembly possibly cure my "blown" motor?

[greg9719]

a few more pics

[JohnnieB]

The backside of the F/R switch is visible in Pic#1 and it tells me you have a DCS drive with an early version of the F/R assembly, so mention the fact it is a DCS drive system when asking electrical questions.

If it were mine, I send the motor to Plum Quick and let them do their magic on it. (New brushes, new bearing, dress the commutator, etc.)
http://www.plumquick.com/

Then install a #505DCS controller/solenoid kit from Carts Unlimited along with a full set of 4Ga high current cables.
http://www.cartsunlimited.net/Custom_Options.html

Since you don't have any batteries, you have to decide what voltage you are going to run. 36V and 48V are the most common ones.

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You've more or less got a blank canvas, so figure out what you want the end result to be and build towards that goal.

[Springlake]

I am doing a build on a 95 Medalist DCS. Look in on my thread when u can. JohnnieB is the man do as he suggested.
Also look into photobucket. It as made my build postings much easier. Keep us posted...Good Luck

[greg9719]

Got my frame coated. I decided to go with KBS Coatings due to it being cheaper than POR 15 yet rumor is KBS was started by the inventors of POR but left due to disagreements. I got two starter kits and probably could of gotten by with 1 but now I have leftover for other stuff. It played down real smoothed and I'm very pleased with the results.

Since this a budget build I opted to order an add-a-leaf kit instead of getting HD or Medium duty springs. I ordered the kit from Carts Parts Plus and must say shipping was extremely fast and prices a great too. I also ordered new bushings and sleeves from them. I gotta repaint the original ugly leafs before I install them though.

[Springlake]

Keep it rolling Greg. I am a little bit ahead of you, today I put on the tires.
Take a look at your brakes. Sitting like your cart was you should probably have rust galore.

[greg9719]

Got my 6" lift installed.

Also cleaned and reinstalled the brake cables. Put the stock front tires on and one tie rod installed. Need to order a new passenger side tie rod too due to it being missing when I acquired the cart. Gonna grab some brake clean and have some new brake shoes that I hope to install Wednesday and I'll be back on a rolling chassis.

I picked up an ez go rivet kit last week and will start getting her put back together soon.

[Springlake]

Originally Posted by greg9719

Got my 6" lift installed.

Also cleaned and reinstalled the brake cables. Put the stock front tires on and one tie rod installed. Need to order a new passenger side tie rod too due to it being missing when I acquired the cart. Gonna grab some brake clean and have some new brake shoes that I hope to install Wednesday and I'll be back on a rolling chassis.

I picked up an ez go rivet kit last week and will start getting her put back together soon.

Getting it done aren't ya!!

Hey about that rivet kit. I too bought the kit. Its crazy the size and number of rivets. I just could not spend the time figuring it out, Black, not black short, long.. So before you start I thought id tell you my plan.


I took a 3/16 drill bit and drilled every hole. I had some long 3/16 rivets left from a roof project. I used those rivets on every hole in the cart and it was great..No worries or siffering (redneck term for figuring it out) Also it has been talked about that using a air rivet gun would be an advantage. I must have spaced it our over a few days, but I found it easy. One thing I am glad though is my gun has a swivel head. The front cowl attachment could have been a bear if not for the swivel..

[Springlake]

Greg one more thing. Check your shock length. I had to use extensions. Of which I have two left if you need a set.

[greg9719]

Made some more progress today.

The leftover lbs rust coating I had hardened up in the jar I'd poured it into. So I picked up a can of rustoleum spray undercoating. I coated the floor pans and was very pleased with the results. Reinstalled them and cleaned the dash up and put it back in place. Cleaned up the floor mat and got it in. I left all the back rivets out for the firewall/front panel of rear body.
Still have to order a new battery tray and I think I'm going to do a camp vinyl wrap so I'm gonna do that with the panels off.

The steering column is just sitting for now. The bottom is flaking so I need to get some more undercoating and spray it.

I tore into the brakes and cleaned and greased everything that needed to be. Need to get a socket to torque the axle nuts. They're just hand tight for now.

Yea I got the rivet kit and was tired of trying to figure them out. I just used some 3/16 x 1/2 rivets I already had so far. I guess at least I'll use the black rivets on the dash from the kit so its not a complete waste.

I'll have to check on shocks. Mined were so worn and I had to sawzall the rears off and they went in the trash. I'll definitely let ya know when I get to that point.