Melex Body and Brake questions

[TLB Nut]

Hi all! Last season I put a 1979 2 stroke EzGo back on the road. I learned a lot of stuff from that and found the joys of some 1 off issues to these earlier carts.

That leads me to today, I just rescued a early Melex Model 212 S/N: 153354 (So early 1980s or late 70s?). It moves under it's own power but is rusted bad.

My first question is the unique braking system on the early Melex. The only brake on this cart is directly off the electric motor. This seams to be weak on mine at the moment. Also parts and info on the system are nearly impossible to locate. Any info on this would be great.

Ok the really big question is the rusty body and inner battery support that does not exist. Any clues or hints on how to take apart the body. Also in the int rest of saving money/ manhours is there any ezgo bodies I can make fit? Or does anyone out there have old Melex body panels, I could buy from you?

Thanks for the help,
Scott

[mixdenny]

The brakes should not be too difficult as long as the brake drum and shoe are OK. If the lining on the shoe is bad I would think a brake shop could rivet a new lining. I found a new cable for mine on Ebay. I did away with the seat brake as everything was too rusty. You can find suitable springs at Ace Hardware or McMaster-Carr. The turnbuckle is readily available but get a load rated one from McMaster-Carr. Mine was very rusty so I replaced the body and the rear screw part and left the front screw portion on the pedal assembly as it is a different style. They just screw together, they are 5/16"-18 threads. You do need to tighten the turnbuckle until the shoe just barely releases when not being applied as there is not a whole lot of travel in the system. Mine will lock the wheels on gravel. You will need to install the cable in place and place cable clamps on as it comes with a long length of cable. I used swage on clamps which are much better then the U bolt style. Home Depot has the clamps and thimbles. You need a Nicopress style of swaging tool. I think I got mine at Home Depot also, long ago.You absolutely need the thimble as the brake pedal travel will be taken up when the loop of cable compresses without the thimble.

See my thread in the Restoration forum about "The Old Gray Melex comes to life" for rebuilding the battery boxes. I cut out all the old metal and made new pans.

The body is one piece, there aren't any body panels. It's cut and weld.

Dennis