Newbie doing a teardown/rebuild on a 96 DCS TXT

[Kingpaul]

OK, here we go! Bought the cart for $250 on Craigslist. Under seats is in terrible shape. It is a 36 volt. My 14 year old son and I are going to rebuild it. No experience with carts, mechanically inclined, but not so much electrically! Once my knowledge base is up to the level of this board's, I will contribute the same way I do on my gun forum, and boat forum. In the meantime, I sure would appreciate tips and guidance. Here are some questions. Sorry so needy!

1) How do you remove body panels? Looks like small pop rivets hold everything on. Then, how do you re-attach?
2) How do you know if components are good? I am tearing out the rusted-out battery tray and installing a new one. I want to completely do a frame-up restore; should I remove F/R switch, solenoid, controller, etc, etc, and scrap all of the wiring? I want to do it right.
3) Any recommendations on frame paint?
4) Can floor-mat be repainted, or replace?
5) I'm sure I will be in touch with ScottyB again for electronics, wiring, cables, etc., but would love recommendations. Would like 23 MPH and decent torque.
6) Can I/Should I change to 48 volt?
I realize that alot of these questions are subjective, but I really would like thoughts and opinions. I will post pics of before and progress if someone will tell me how.
Thank you very much!

[scottyb]

23mph is doable with 48v and 400amp controller in a DCS cart. DCS carts make more speed than a series cart and more torque than a PDS cart, Drill out all the rivets (most use a 3/16ths drill) to remove panels, dash, floor (5/16 drill) pan, etc. You will want to replace all the cabling and single strands of secondary wire you see... Take special care not to damage the DCS F&R as those MS are expensive and the units are getting harder to find. Of course you could replace it with a toggle R&R.... good luck and post pics!

[Kingpaul]

Thanks Scotty! Do I use rivets when I re-assemble? Is this a standard rivet tool, or something specific to EZGO?

Where do I learn how to post pics?

Thanks again. I'll be back with you for components when I start to rebuild.

[scottyb]

Go to Shopezgo.com and buy the body rivet kit and the dash rivet kit. You will need some standard 5/16 rivets for the floor pan. You can get rivets and gun at hardware store or buy a pneumatic gun at HF.

Picture posting 101 is around here someplace ....

[rib33024]

Welcome to BGW



Here's one way,, or start a photobucket account, or a imageshack account









( let the forum host the picture. )


click "Go To Advanced"

then click "Manage Attachments"

click "Choose" in the pop-up window

select the file(s) from your computer

click "Upload"

close pop-up after files complete uploading.

click "Submit Reply"




"Go Advanced"



"Manage Attachments"




"Choose"- click on what you want to post, - then click -"Upload" wait a few sec

[Kingpaul]

Here she is:

[scottyb]

I hope nobody was hurt in the roll over accident!

[Kingpaul]

That's an actual photo; I installed the anti-gravity air in the tires. Makes parking and storing much easier!

[camaroluvz28]

Originally Posted by scottyb

I hope nobody was hurt in the roll over accident!

[Furyous]

Nice! Great father-son project. I recommend POR-15's rust prep and paint. I used it in the restoration of my Plymouth, and you can paint it directly over any rust and it will never rust again. The only drawback is that it can break down in uv light, so I recommend a top coat in the color if your choice. Not that the frame would see much sun, but it just takes a couple of rattle cans and a half hour to rust proof the rude for life, and you'll have some piece of mind that you'll never have to do it again.