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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 06-12-2012, 03:00 PM   #1
tyhuck
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Default 86 Marathon Hunting Buggy Build

I recently came across this 86 EzGo at a great price...FREE!!!

I figured that I could put some money into it and still come out ahead of buying a newer one. So far Ive replaced the resitor coil, added some rear lift blocks, and modified the front suspension to get 5" of lift. Ive also replaced most of my battery cables with 4g wire and new terminal rings. I havent gotten them all because I ran out of wire. So far Ive got about $300 in it.

I know that it will need new batteries and Im gonna get taller tires, but other than that, I really dont know what I should upgrade or replace. Ive been toying with the idea of a 48v conversion, but I want to keep this on a budget. I would rather not spend the same amount of money on an 86 model cart that I could spend on a newer one that is already rigged out.

Here it is the day I got it home. All 4 flat tires and completly dead.



Then came the lift



All I did was flip the spindle shafts to the downward position and re-weld them.



The rear lift was pretty much just like the other budget type lifts that you can find all over online.
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Old 06-12-2012, 03:43 PM   #2
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Default Re: 86 Marathon Hunting Buggy Build

Sorry, Double post. PLease delete this one.
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Old 06-12-2012, 08:33 PM   #3
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Default Re: 86 Marathon Hunting Buggy Build

Enjoy the build, it's always better when you ride something that you built/improved.
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Old 06-13-2012, 10:56 AM   #4
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Default Re: 86 Marathon Hunting Buggy Build

I will. I decided to bite the bullet and go with a full on resto mod. I cant afford to upgrade much right now, but I can fix whats bad on it so that it doesnt get worse waiting for funds.

I completely tore down the cart as much as it could be. Now Im gonna sand blast it and rebuild the battery trays. Then Im gonna prime it and coat the battery rack and underside with some undercoating to try to combat future corrosion issues. Then the outside will either get a rattle can camo job or a rattle can flat black. Then a front and rear rack should be all it needs to be "in-the-woods functional".

Main concern it stopping the rot right now.
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Old 06-13-2012, 02:18 PM   #5
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Default Re: 86 Marathon Hunting Buggy Build

Heavy gauge wires all the way around, a HD F&R switch, a new solenoid, and a new wiper, wiper board, and contacts. All these made a world of difference in my cart. Much more torque that it originally had, even with the 22" tires
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Old 06-13-2012, 03:24 PM   #6
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Default Re: 86 Marathon Hunting Buggy Build

Quote:
Originally Posted by tyhuck View Post
Then Im gonna prime it and coat the battery rack and underside with some undercoating to try to combat future corrosion issues.
I have no proof to back up my belief, but I used undercoating and found it to be too "soft" for use under my batteries, as they slide around some when messin' with them. I stripped it off and used truck bed liner, with the theory that truck beds have to be pretty tough, since they're made to have stuff thrown in and slid around.
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Old 06-13-2012, 06:27 PM   #7
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Default Re: 86 Marathon Hunting Buggy Build

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Originally Posted by barcloverranch View Post
Heavy gauge wires all the way around, a HD F&R switch, a new solenoid, and a new wiper, wiper board, and contacts. All these made a world of difference in my cart. Much more torque that it originally had, even with the 22" tires
GOt most of the wires replaced already, new coil, and plan on eventually replace all of the electronics. Right now though, the frame is a priority.

Washed the parts today and picked up the sand blaster from my father-in-law. Gonna try to start stripping tomorrow.
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Old 06-14-2012, 05:20 PM   #8
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Default Re: 86 Marathon Hunting Buggy Build

Awesome, yeah take care of the frame first, everything else is replaceable
Keep us posted how it goes
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Old 06-14-2012, 08:40 PM   #9
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Default Re: 86 Marathon Hunting Buggy Build

Got it somewhat stripped, but ran out of sand. Gonna buy some more this weekend and try to finish it up. ONly bad part is the battery rack and the cross-brace that the front of the battery trays sit on. Probably will have to replace that too, but it doesnt look too bad.
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Old 06-14-2012, 08:44 PM   #10
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Default Re: 86 Marathon Hunting Buggy Build

BTW, is there anything that anyone has found to stop the battery tray from rusting out in the future? I mean something to coat the steel with, not just replacing it with aluminum. While aluminum would be nice, Its pricey, and our TIG welder is on the fritz..
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