Complete Golf Cart Rebuild - TexasBowhunter.com Community Discussion Forums

swoledouglas · 11-17-2011, 12:28 PM

I have been driving this old tired golf cart around for a few years and although it works fine it needs some upgrades. I am starting with a Melex 212 that was made around 1980. I am going to be converting it from a resistor set up to a solid state speed control. Then i am going to add 2 more batteries to make it a 48 volt. I am going to have the motor rebuilt by Plum Quick, and I am going to lift it a little and put some bigger wheels and tires on it. By the time I am done i will have a very cool cart. Plus almost everything has to be hand built so I get to play with my welder and flex my brain a little. Here are some starting pics.

Stros · 11-17-2011, 12:31 PM

will be watching good luck.

bassmatt72 · 11-17-2011, 02:29 PM

sweet!! I'm watching too! I have a 99 club car that I did some upgrading to.

whitie · 11-17-2011, 02:33 PM

Plumquick did my motor on my first cart that I converted to 48volts...they are good people to deal with. I just converted my resistor to controller and about to put new batteries in for the final test run. What controller are you going with? Its a fun process.

altabonita · 11-17-2011, 02:42 PM

Good luck with it.

TXArrowSlinger · 11-17-2011, 03:35 PM

I have been looking at doing one of these......definately be following this thread. Good luck and eep us posted.

Placek05 · 11-18-2011, 12:10 PM

That is going to be quite an undertaking, but just my kind of project. Sounds like fun. Cant wait to see progress pics.

swoledouglas · 11-18-2011, 01:44 PM

Quote:

Originally Posted by whitie

Plumquick did my motor on my first cart that I converted to 48volts...they are good people to deal with. I just converted my resistor to controller and about to put new batteries in for the final test run. What controller are you going with? Its a fun process.

I am going to go with an altrax 500 amp non programmable controller. I am getting everything as a package from Carts Unlimited.

swoledouglas · 11-18-2011, 01:48 PM

Quote:

Originally Posted by whitie

Plumquick did my motor on my first cart that I converted to 48volts...they are good people to deal with. I just converted my resistor to controller and about to put new batteries in for the final test run. What controller are you going with? Its a fun process.

I have heard nothing but good things about Plum Quick so far. All of their reviews have been positive. It may be a while before I get the motor built because the speed controller swap will eat up alot of what I have saved for it right off the bat. I am doing the lift myself so that will just cost me scrap metal, wire and gas for my welder.

kraigrrr · 11-18-2011, 01:54 PM

cool! Do you collect weed eaters???

whitie · 11-18-2011, 01:54 PM

Best of luck...looking forward to seeing the upgrades.

Tejas Wildlife · 11-18-2011, 07:34 PM

I'm following this closely. I have a '98 Ezgo that needs a solid state upgrade.

Sticks&Strings · 11-20-2011, 08:01 PM

I will be watching. What is solid state and what is resistor and how do u know which one you have? I pulled home an older ez go today and need batteries first, then on to cosmetics.

sports · 11-21-2011, 03:03 PM

I am definately interested in following this thread. I bought this a few months back with the lift kit, tires and bed already installed. I have had to replace the batteries but am looking to do some upgrades myself. Primarily a camo paint job, light kit, and whatever I need to do to get a little more speed going uphills. Best I can tell it is a 1979 model (model # 79H17).

swoledouglas · 11-21-2011, 03:31 PM

Quote:

Originally Posted by kraigrrr

cool! Do you collect weed eaters???

LOL No, I repair them. Those are the ones that I pull parts off of.

swoledouglas · 11-21-2011, 03:33 PM

Quote:

Originally Posted by sports

I am definately interested in following this thread. I bought this a few months back with the lift kit, tires and bed already installed. I have had to replace the batteries but am looking to do some upgrades myself. Primarily a camo paint job, light kit, and whatever I need to do to get a little more speed going uphills. Best I can tell it is a 1979 model (model # 79H17).

My cart is a knock off of your cart. Melex copied EZGO until the went under.

swoledouglas · 11-21-2011, 03:34 PM

Quote:

Originally Posted by Sticks&Strings

I will be watching. What is solid state and what is resistor and how do u know which one you have? I pulled home an older ez go today and need batteries first, then on to cosmetics.

The coils under the seat are resistor coils. newer carts don't have these.

dac6933 · 11-28-2011, 10:00 PM

swoledouglas · 11-29-2011, 08:02 AM

I got the rear half of the sheet metal off. There were flat head screws every 4 inches on this thing. and the rear is the easiest part to disassemble.

swoledouglas · 11-30-2011, 05:41 PM

I got it almost completely stripped. Getting ready to lift the rear. There is no where near as much corrosion as I expected. Just some surface rust. It is moving right along with no issues so far.

I am amassing quite a pile of parts as you can see.

swoledouglas · 12-06-2011, 10:21 AM

Got the rear end out of it getting it ready to build the lift.

Joey~AP · 12-06-2011, 10:29 AM

Sweet project!

swoledouglas · 01-05-2012, 05:02 PM

Got the lift done

Now I just have to clean up my welds and prime it. I lifted the front 6" and the rear 7". I am happy with the progress so far. There is a lot of work to do yet but it will be worth it when its done.

Sergio_III · 01-05-2012, 08:08 PM

Following this closely. Have 2 to build over the summer and this will help a lot.

DH2 · 01-06-2012, 04:24 PM

Did you build the lift kit yourself???

Bonehead · 01-08-2012, 05:23 PM

Sweet, lots of fun giving them a make-over! I just finished mine last month.

1991 EZ Go Marathon before and after.

swoledouglas · 01-08-2012, 09:40 PM

Awesome!!

dgh · 01-09-2012, 10:05 AM

have a 96 ezgo that i'm working on

fisher__man · 01-09-2012, 01:43 PM

what does it cost to rebuild one like that?
I know of a few laying around that I could probably pick up for cheep.
thanks

swoledouglas · 01-19-2012, 03:47 PM

Quote:

Originally Posted by fisher__man

what does it cost to rebuild one like that?
I know of a few laying around that I could probably pick up for cheep.
thanks

Well, it all depends on how far you want to go with it. I am really gong overboard with it and I will have $2500-$3000 in it when it is all said and done. You can get out MUCH cheaper depending on what you are wanting to accomplish with it.

swoledouglas · 01-19-2012, 03:51 PM

More pics

Codypatt1 · 02-17-2012, 09:54 PM

Following along also. Just picked me up an 88 ezgo.

swoledouglas · 05-09-2012, 12:48 PM

I just ordered the parts today to get this thing moving again! I will be back at it soon.

Stan R · 05-09-2012, 06:33 PM

It is easy for projects to get set aside... looking forward to some updated pics...

swoledouglas · 05-31-2012, 04:35 PM

All the parts are in!!! I am installing them slowly so I take my time and don't make mistakes. Here are some recent pics.

swoledouglas · 06-11-2012, 08:31 AM

Here are some updated pics

swoledouglas · 06-12-2012, 01:53 PM

Batteries are in the cart. All I have to do now it get it wired and test it!!!

Codypatt1 · 06-12-2012, 06:58 PM

Make sure you double/triple check the wiring!

Awaiting to see moving Cart video!!

lilbradford · 06-15-2012, 01:48 PM

Keep going. Looks great!

swoledouglas · 06-20-2012, 07:45 AM

It's Alive!!! I got all the new wires made and put in yesterday and the wheels moved under its own power for the first time since November. I have a few more things to do before it is road worthy but the hard part is over. It is about time to have fun!

DYARB · 06-20-2012, 08:24 AM

Congrats

swoledouglas · 06-20-2012, 10:46 AM

Took my first ride a few minutes ago!!!

swoledouglas · 06-29-2012, 08:06 AM

Wheels and Tires are on their way!!

BowSlayer · 06-29-2012, 09:53 PM

Awesome build! Great job! Can't wait to see finished pictures!

swoledouglas · 10-04-2012, 08:42 AM

Quote:

Originally Posted by BowSlayer

Awesome build! Great job! Can't wait to see finished pictures!

Sorry it took so long. I have been really busy at work and havent had time to finish it. I got the wheels and tires mounted and the spacers on. I still have seats and lights to work on but it is a functioning cart and it looks pretty good I think.

tod · 10-04-2012, 09:20 AM

Looking good.

LEGION · 10-06-2012, 08:24 AM

Looks great.

Bowhunter9790 · 10-06-2012, 08:32 AM

Looking good

swoledouglas · 10-08-2012, 08:27 AM

Before and After

11-17-2011, 12:28 PM	#1
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	Complete Golf Cart Rebuild I have been driving this old tired golf cart around for a few years and although it works fine it needs some upgrades. I am starting with a Melex 212 that was made around 1980. I am going to be converting it from a resistor set up to a solid state speed control. Then i am going to add 2 more batteries to make it a 48 volt. I am going to have the motor rebuilt by Plum Quick, and I am going to lift it a little and put some bigger wheels and tires on it. By the time I am done i will have a very cool cart. Plus almost everything has to be hand built so I get to play with my welder and flex my brain a little. Here are some starting pics. Attached Images

11-21-2011, 03:03 PM	#14
sports Four Point Join Date: Mar 2009 Location: Danbury Hunt In: Looking	Very Interested I am definately interested in following this thread. I bought this a few months back with the lift kit, tires and bed already installed. I have had to replace the batteries but am looking to do some upgrades myself. Primarily a camo paint job, light kit, and whatever I need to do to get a little more speed going uphills. Best I can tell it is a 1979 model (model # 79H17). Attached Images

11-28-2011, 10:00 PM	#18
dac6933 Pope & Young Join Date: Jan 2007 Location: Allen,Tx	nice

11-30-2011, 05:41 PM	#20
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	I got it almost completely stripped. Getting ready to lift the rear. There is no where near as much corrosion as I expected. Just some surface rust. It is moving right along with no issues so far. I am amassing quite a pile of parts as you can see. Attached Images

12-06-2011, 10:29 AM	#22
Joey~AP Administrator Join Date: Oct 2006 Location: Right behind you...watchin. Hunt In: Texas	*Sweet project!* __________________ *To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.* We're paratroopers, Lieutenant. *We're supposed to be surrounded......* /l _ ,[____], l---- L-- -OlllllllO- ()_)--()_)---o-)_)**

11-17-2011, 12:31 PM	#2
Stros Ten Point Join Date: Nov 2008 Location: Katy, Texas Hunt In: Roosevelt, Texas and Galveston Bay	will be watching good luck.

11-17-2011, 02:29 PM	#3
bassmatt72 Ten Point Join Date: Apr 2009 Location: Belton TX Hunt In: NW Coryell County	sweet!! I'm watching too! I have a 99 club car that I did some upgrading to.

11-17-2011, 02:33 PM	#4
whitie Six Point Join Date: Mar 2007 Location: Flower Mound Hunt In: Junction, Virginia, Grayson	Plumquick did my motor on my first cart that I converted to 48volts...they are good people to deal with. I just converted my resistor to controller and about to put new batteries in for the final test run. What controller are you going with? Its a fun process.

11-17-2011, 02:42 PM	#5
altabonita Ten Point Join Date: Nov 2008	Good luck with it.

11-17-2011, 03:35 PM	#6
TXArrowSlinger Ten Point Join Date: Jul 2009 Location: Ft. Huachuca, Arizona Hunt In: Ft. Huachuca, Benson, Bisbee, anywhere I am invited, and anywhere possible!!!!	I have been looking at doing one of these......definately be following this thread. Good luck and eep us posted.

11-18-2011, 12:10 PM	#7
Placek05 Nubbin' Buck Join Date: Oct 2011 Location: Floresville Hunt In: S.Texas	That is going to be quite an undertaking, but just my kind of project. Sounds like fun. Cant wait to see progress pics.

11-18-2011, 01:54 PM	#10
kraigrrr Ten Point Join Date: Nov 2009 Location: Frisco, TX Hunt In: Grayson county, Hagerman area	cool! Do you collect weed eaters???

11-18-2011, 07:34 PM	#12
Tejas Wildlife Ten Point Join Date: Oct 2008 Location: Groesbeck, TX Hunt In: Where ever I happen to be!	I'm following this closely. I have a '98 Ezgo that needs a solid state upgrade.

11-20-2011, 08:01 PM	#13
Sticks&Strings Ten Point Join Date: Oct 2006 Location: Magnolia, TX/ Kinney& sometimes Leon	I will be watching. What is solid state and what is resistor and how do u know which one you have? I pulled home an older ez go today and need batteries first, then on to cosmetics.

11-29-2011, 08:02 AM	#19
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	I got the rear half of the sheet metal off. There were flat head screws every 4 inches on this thing. and the rear is the easiest part to disassemble.

12-06-2011, 10:21 AM	#21
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	Got the rear end out of it getting it ready to build the lift.

01-05-2012, 05:02 PM	#23
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	Got the lift done Now I just have to clean up my welds and prime it. I lifted the front 6" and the rear 7". I am happy with the progress so far. There is a lot of work to do yet but it will be worth it when its done. Attached Images

01-05-2012, 08:08 PM	#24
Sergio_III Eight Point Join Date: Oct 2006 Location: Laredo, TX	Following this closely. Have 2 to build over the summer and this will help a lot.

01-06-2012, 04:24 PM	#25
DH2 Four Point Join Date: Oct 2011	Did you build the lift kit yourself???

01-08-2012, 05:23 PM	#26
Bonehead Ten Point Join Date: Oct 2010 Location: Kingwood Tx Hunt In: Burnet Co	Sweet, lots of fun giving them a make-over! I just finished mine last month. 1991 EZ Go Marathon before and after. Attached Images

01-08-2012, 09:40 PM	#27
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	Awesome!!

01-09-2012, 10:05 AM	#28
dgh Ten Point Join Date: Jan 2011 Location: Conroe Hunt In: Madison And Walker County	have a 96 ezgo that i'm working on

01-09-2012, 01:43 PM	#29
fisher__man Four Point Join Date: Oct 2006 Location: Chambers county	what does it cost to rebuild one like that? I know of a few laying around that I could probably pick up for cheep. thanks

01-19-2012, 03:51 PM	#31
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	More pics Attached Images

02-17-2012, 09:54 PM	#32
Codypatt1 Ten Point Join Date: Mar 2007 Location: Rowlett Hunt In: S.Central OK/ Beeville, TX	Following along also. Just picked me up an 88 ezgo. Attached Images

05-09-2012, 12:48 PM	#33
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	I just ordered the parts today to get this thing moving again! I will be back at it soon.

05-09-2012, 06:33 PM	#34
Stan R Pope & Young Join Date: Apr 2008 Location: 77077 Hunt In: Madison and Colorado County	It is easy for projects to get set aside... looking forward to some updated pics...

05-31-2012, 04:35 PM	#35
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	All the parts are in!!! I am installing them slowly so I take my time and don't make mistakes. Here are some recent pics. Attached Images

06-11-2012, 08:31 AM	#36
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	Here are some updated pics Attached Images

06-12-2012, 01:53 PM	#37
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	Batteries are in the cart. All I have to do now it get it wired and test it!!!

06-12-2012, 06:58 PM	#38
Codypatt1 Ten Point Join Date: Mar 2007 Location: Rowlett Hunt In: S.Central OK/ Beeville, TX	Make sure you double/triple check the wiring! Awaiting to see moving Cart video!!

06-15-2012, 01:48 PM	#39
lilbradford Six Point Join Date: May 2012 Location: Katy, Tx Hunt In: Anywhere I can find	Keep going. Looks great!

06-20-2012, 07:45 AM	#40
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	It's Alive!!! I got all the new wires made and put in yesterday and the wheels moved under its own power for the first time since November. I have a few more things to do before it is road worthy but the hard part is over. It is about time to have fun!

06-20-2012, 08:24 AM	#41
DYARB Six Point Join Date: May 2012 Location: Forney TX Hunt In: Young County	Congrats

06-20-2012, 10:46 AM	#42
swoledouglas Ten Point Join Date: Dec 2008 Location: Little River Academy, Texas Hunt In: bell county, Texas	Took my first ride a few minutes ago!!!