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Old 11-17-2011, 12:28 PM   #1
swoledouglas
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Default 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.
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Old 11-17-2011, 12:31 PM   #2
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will be watching good luck.
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Old 11-17-2011, 02:29 PM   #3
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sweet!! I'm watching too! I have a 99 club car that I did some upgrading to.
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Old 11-17-2011, 02:33 PM   #4
whitie
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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.
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Old 11-17-2011, 02:42 PM   #5
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Good luck with it.
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Old 11-17-2011, 03:35 PM   #6
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I have been looking at doing one of these......definately be following this thread. Good luck and eep us posted.
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Old 11-18-2011, 12:10 PM   #7
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That is going to be quite an undertaking, but just my kind of project. Sounds like fun. Cant wait to see progress pics.
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Old 11-18-2011, 01:44 PM   #8
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Quote:
Originally Posted by whitie View Post
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.
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Old 11-18-2011, 01:48 PM   #9
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Quote:
Originally Posted by whitie View Post
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.
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Old 11-18-2011, 01:54 PM   #10
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cool! Do you collect weed eaters???
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Old 11-18-2011, 01:54 PM   #11
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Best of luck...looking forward to seeing the upgrades.
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Old 11-18-2011, 07:34 PM   #12
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I'm following this closely. I have a '98 Ezgo that needs a solid state upgrade.
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Old 11-20-2011, 08:01 PM   #13
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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.
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Old 11-21-2011, 03:03 PM   #14
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Default 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).
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Old 11-21-2011, 03:31 PM   #15
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Quote:
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cool! Do you collect weed eaters???
LOL No, I repair them. Those are the ones that I pull parts off of.
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Old 11-21-2011, 03:33 PM   #16
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Quote:
Originally Posted by sports View Post
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.
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Old 11-21-2011, 03:34 PM   #17
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Quote:
Originally Posted by Sticks&Strings View Post
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.
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Old 11-28-2011, 10:00 PM   #18
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nice
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Old 11-29-2011, 08:02 AM   #19
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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.
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Old 11-30-2011, 05:41 PM   #20
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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.
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Old 12-06-2011, 10:21 AM   #21
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Got the rear end out of it getting it ready to build the lift.
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Old 12-06-2011, 10:29 AM   #22
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Sweet project!
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Old 01-05-2012, 05:02 PM   #23
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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.
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Old 01-05-2012, 08:08 PM   #24
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Following this closely. Have 2 to build over the summer and this will help a lot.
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Old 01-06-2012, 04:24 PM   #25
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Did you build the lift kit yourself???
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Old 01-08-2012, 05:23 PM   #26
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Sweet, lots of fun giving them a make-over! I just finished mine last month.

1991 EZ Go Marathon before and after.
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Old 01-08-2012, 09:40 PM   #27
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Awesome!!
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Old 01-09-2012, 10:05 AM   #28
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have a 96 ezgo that i'm working on
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Old 01-09-2012, 01:43 PM   #29
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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
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Old 01-19-2012, 03:47 PM   #30
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Quote:
Originally Posted by fisher__man View Post
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.
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Old 01-19-2012, 03:51 PM   #31
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More pics
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Old 02-17-2012, 09:54 PM   #32
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Following along also. Just picked me up an 88 ezgo.
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Old 05-09-2012, 12:48 PM   #33
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I just ordered the parts today to get this thing moving again! I will be back at it soon.
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Old 05-09-2012, 06:33 PM   #34
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It is easy for projects to get set aside... looking forward to some updated pics...
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Old 05-31-2012, 04:35 PM   #35
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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.
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Old 06-11-2012, 08:31 AM   #36
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Here are some updated pics
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Old 06-12-2012, 01:53 PM   #37
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Batteries are in the cart. All I have to do now it get it wired and test it!!!
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Old 06-12-2012, 06:58 PM   #38
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Make sure you double/triple check the wiring!

Awaiting to see moving Cart video!!
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Old 06-15-2012, 01:48 PM   #39
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Keep going. Looks great!
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Old 06-20-2012, 07:45 AM   #40
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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!
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Old 06-20-2012, 08:24 AM   #41
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Congrats
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Old 06-20-2012, 10:46 AM   #42
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Took my first ride a few minutes ago!!!
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Old 06-29-2012, 08:06 AM   #43
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Wheels and Tires are on their way!!
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Old 06-29-2012, 09:53 PM   #44
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Awesome build! Great job! Can't wait to see finished pictures!
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Old 10-04-2012, 08:42 AM   #45
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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.
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Old 10-04-2012, 09:20 AM   #46
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Looking good.
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Old 10-06-2012, 08:24 AM   #47
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Looks great.
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Old 10-06-2012, 08:32 AM   #48
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Looking good
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Old 10-08-2012, 08:27 AM   #49
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Before and After
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