EZGO TXT BigBattery HSKY, Alltrax conversion, 36-48 conversion results

[once_for_all]

My battery arrives tomorrow. I asked BB for a 4 gauge SB175, who responded that they do not carry that size, referred me to batterycables, and said be sure to get the "grey" style as that is what goes into their battery.

When you have yours finalized, post photos! I need to lay everything out, including the new carts unlimited rocker FNR conversion and 48v 400amp solenoid, and start listing the cables I need. Looks like everything will be 3/8" ring except the motor at 5/16". Battery cables does the mix and match of sizes. Thought about ordering supplies and a crimper but their price for a built cable looks cheaper.

[superfan86]

Originally Posted by once_for_all

My battery arrives tomorrow. I asked BB for a 4 gauge SB175, who responded that they do not carry that size, referred me to batterycables, and said be sure to get the "grey" style as that is what goes into their battery.

When you have yours finalized, post photos! I need to lay everything out, including the new carts unlimited rocker FNR conversion and 48v 400amp solenoid, and start listing the cables I need. Looks like everything will be 3/8" ring except the motor at 5/16". Battery cables does the mix and match of sizes. Thought about ordering supplies and a crimper but their price for a built cable looks cheaper.

I bought a 5/16" distribution block and used the screw holes from the handles and some sticky tape to secure it. Everything fits nicely on it except the new LiFePo4 shut bolts are 3/8, so I'm navigating that issue currently. Will likely just swap the lug on the block for the negative battery to 3/8" and call it a day.

I'm cleaning up more as I go and am holding off on ordering cables until I install my updated shunt today, but I don't see much deviating except changing the Anderson lug to 3/8" to make it all work.

My cart has 4ga Controller-motor, so I'm going to stick with that for now. Everything else I'm overbuying just to have available. The price difference between the cables sizes is negligible.

Order list:
1x Anderson-lug 12" 1/0 AWG (maybe 18" just to have room to manage cables)
1x Golf Cart Battery Cable 2 AWG 12" RED Terminal block Positive -> Controller
1x Golf Cart Battery Cable 2 AWG 12" BLACK Controller -> Solenoid
1x Golf Cart Battery Cable 2 AWG 20" BLACK Controller -> Terminal Block Negative

Ignore the "fake cable" rope. I was using it to measure some lengths.

Shunt Meter I swapped to

[superfan86]

Originally Posted by once_for_all

My battery arrives tomorrow. I asked BB for a 4 gauge SB175, who responded that they do not carry that size, referred me to batterycables, and said be sure to get the "grey" style as that is what goes into their battery.

When you have yours finalized, post photos! I need to lay everything out, including the new carts unlimited rocker FNR conversion and 48v 400amp solenoid, and start listing the cables I need. Looks like everything will be 3/8" ring except the motor at 5/16". Battery cables does the mix and match of sizes. Thought about ordering supplies and a crimper but their price for a built cable looks cheaper.

Finally got everything cleaned up and new 2ga cables installed.

I ended up going directly from the battery to controller/solenoid with my anderson cable and then running wires back over to the terminal block. Saved me 2 cables and an extra 2 feet of wire. Also realized my terminal block was only rated for 250 amps.

My short runs are 13 inches. If I ordered again I'd do 14-15 in to give myself a little more breathing room to twist those thick cables around, but it works as is.

My long run Anderson is 18 inch. You couldn't go any shorter in my configuration, but if you go longer it jumps to 6" increments, which would have been excessive. I think this works fine and I'm not seeing any stress on the connections.

I'm going to operate with this configuration and be happy. I'm sure my stock 36v AMD motor running at 48v is my bottleneck now, so even with a 400 amp controller I don't see how the 4ga cables I have left could be a significant factor in my performance. If I end up going with an aftermarket motor down the road, I'll upgrade those cables at that time.

30 mph is WAY more than enough for this family hauler. Any more power/torque would certainly result in major wheelies, which is an unsafe condition I'd like to avoid.

[once_for_all]

Very nice! My cables are late in arriving. Busbars here. Am replacing the FNR setup with the Carts Unlimited reversing contactor. Relocating the contactor from the front of the controller to the open bay to the rear of the Husky. 3 of the 4 motor cables will be shorter and the M- to A2 the same.

The 2gauge cables are rated at 210amps, so the 250amp busbar should be up to the job.

[Brent_Blacke]

Great info, thank you!! makes me excited to keep my PDS!! Are you really running 22" tires on stock suspension? No lift or HD rear spring? Any rubbing?

Originally Posted by superfan86

I know a lot of folks have been asking about the performance gains from different combos, so I wanted to add another thread for the greater good.

05 EZGO TXT PDS. Stock AMD 36v motor. Factory lift on 22" tires

Stage 1:
Freedom Controller
RoyPow 105 36v

Speed remained the same (20 mph tops). Acceleration and handling excellent. Significant increase in acceleration and torque

Night and day difference between lead acid and likely anyone ever needs.

Stage 2:
Alltrax 400 controller (450 amp peak output configured)
Lead Acid 36v
Comparable acceleration performance to Stage 1, which was surprising. Battery fatigued after about a mile, but still remained better than "stock"
Top Speed increased to 25, but took awhile to get there. Realistic top speed is 22-23.


Stage 3:
Alltrax 400 controller (450 amp peak output configured)
BigBattery HSKY 103 48v (350 amp peak output)
Obviously a huge difference.
Cart does wheelies if floored from a stop (battery is in front tray to help). Top speed 31 MPH and no trouble getting there. 0-25 without any effort and nearly instant. Realistic top speed is about 28. Torque monster and weight reduction makes you forget that curbs exist.
Stock brakes are no longer adequate. YOU NEED TO UPGRADE NOW

Please forgive the wiring mess. Terminal blocks are arriving today...

[superfan86]

Originally Posted by Brent_Blacke

Great info, thank you!! makes me excited to keep my PDS!! Are you really running 22" tires on stock suspension? No lift or HD rear spring? Any rubbing?

Sorry I didn't see this sooner. I have a factory lift, which I believe is 4".

I could fit a 23 but no bigger.