Installing Controller in a EZGO

[BCGC]

I'm thinking about taking out the 6.1 HP motor and the 700 amp controller out of my lifted 1999 ezgo no dcs/pds and installing it into my wifes 2002 ezgo no dcs/pds low rider. since we all know that the forward and reverse switch is the weak link in this type of system, does any one think it will do better in a none lifted cart with 10'' wheels? been through this burn up wire thing to many times i've try'd everthing to stop the pain of burnning thing up. tired of the repairs,but love the speed!do you guy's think it would do better in a lower cart? than in a 4'' lifted carts with 10'' wheels and 22'' tires? it will take a couple of hours to do the swap what do you think

 

[HotRodCarts]

You should have less heat related problems with the smaller tires. Use a minimum of 4 gauge welding cables for ALL the cables and HD buss bars in the F&R switch.

 

[BCGC]

less heat or no heat problems

 

[HotRodCarts]

If everything is set up right you shouldn't have any heat problems unless you'll be driving the cart at slow speeds a lot or running it on hilly terrain. What size cables are you using with this setup on the lifted cart with 22" tires?

 

[BCGC]

1 ga welding cables burn them up like nothing in 2 years 3 f and r switches, copper studs, cables, you name it i changed it.last weekend i found the s1 stud starting to melt away,caught it in time. i have a customer that put in the same system last year. cart ran fine for a month or 2, we installed new trojan batteries last week and every 4 ga wire in the cart are hot to touch. installing new f and r switch into it tonight, hoping to stop the burning for a little while. if you ask me buggies unlimited sold this motor and controller deal with out testing it. i purchased this system from them 3 years ago, the cart flew and still does, the only problem is everyone wanted one so they spent their money and know it's never ending repairs. i have no problem with it, but i hear over and over how people are disappointed in the system they spent so much money on. i was just hoping someone had a better answer. it hard getting people into the golf cart world . i have a couple of customers still willing to go the distance to be differant, but they'll be the first to tell you nobody can come up with a way to fix this problem. there was no word of lifted or non lifted cart, 3 years ago when i was the first to step up to the 6 hp 700 amp controller hd solenoid. the first time i asked about burning up wires buggies suggested to change buss bars?''this wil solve the problem'' now people talk about tire size,cable size, low speed, hills,towing,lifted or not lifted. i guess i need to tell people lifted cart are not made to go fast and next year i guess i'll have to tell them low carts are not either. come on there has to be a better way! we invest so much into it there has to be a better way! hats off to the one who figures it out. best of luck! have a good weekend bcgc i love carting and don't even mind spending money everday, but it gets lonely driving around by yourself when your buddies think your an ass for doing what you do.

 

[HotRodCarts]

I've built quite a few carts with the same setup you have. The only difference I always use D&D motors. BU is now using D&D also (I think) but back then they were using a motor that was prone to problems from some other company. I always tell my customers if they go with a High Speed motor the golf cart is pretty much built for driving on streets with not many hills. Driving slow will also cause heat problems with the HS motors. The bottom line is if you build a cart with a high speed motor and big amp controller there's going to be a lot of maintenance involved to keep it running like it should.

 

[BCGC]

Hot Rod once again to you. i'm posting this in my shop monday. like i stated, i knew getting into it! that there was going to be problems. i tell everyone who gets involved with this stuff, but now i have a little more support. Cartaholics Golf Cart Forum is the right place for golf cart upgrades. thank you for your time

 

[HotRodCarts]

No problem. Thanks for the compliment on the forum. I wish I had a definite answer on solving your problem.

 

[BCGC]

you did, there isn't one. if people want to step up to do, what we are doing. they need to spend and work as hard as we do. thanks for all your help. i'm putting it to rest. have a new project, found a dcs cart that i like to lower. like to shave it down, and keep simple and clean, not looking for comfort just a look people have seen come out of my shop. tired of the lifted and speed monster rat rod cart i have. time to do somthing else. the wife has a stock ezgo txt with nice paint and wheels, every one seem to like it. so the new cart has to be lower than stock and crazy to look at. once again thank you for your help bcgc please take a little time to check out how we do it, in the north east we are just trying to keep up!!

 

[HotRodCarts]

Sounds like a nice project. Keep us posted on the progress and details.