Ford Bronco "woody"
 

I ran across this golf cart while bicycling around the neighborhood. It had this hideous "body" on it, no batteries, but the owner swore it would run. I had some ideas for putting a new body on this, inspired by the fiberglass '57 Chevy body kits and the like. So I took it.

Well, it was not exactly in running condition. Battery cables were missing, the solenoid wasn't connected and was in fact bad. I believe it is an EZGO Marathon late 80's cart. As such, it has a mechanical speed control. I may upgrade electronics someday, but for now I just wanted to get it running. I installed new batteries and all new battery cables. I cleaned up and painted the resistor cage, and cleaned an reconditioned the electrical contacts on the speed control. I replaced the solenoid and wiring. I was relieved when it ran, up on jack stands. But there was more mechanical work to do.

The brake shoes were bad; one broken in half. I replaced those along with the brake cables. I guessed that the shocks were probably original, so I replaced those. Front shocks were actually missing. The ball joints were not so good, so they were all replaced as well. King pins were worn. I found a front axle weldment on closeout, so I installed that, along with new bushings. Cleaned up and painted the rusty leaf springs and other parts such as brake and accelerator pedals and linkages. I installed a temporary floor and seat platform, and I had a running chassis. Steering box was a little wonky, so I installed a rebuild kit with new rack.

More to come.

Re: Ford Bronco "woody"
 

What do you mean hideous? A little mud and paint and she’ll be a supermodel! [emoji6]

Good score though. You know have all sorts of body options... (I’m in CT and have a pretty nice club car body from that era that you can have for free)

You could do a dwarf race car body. There’s a guy on here with one. It’s sweet!

You could buy a kit...

You could make your own crazy body. Either way. Nice score.


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Re: Ford Bronco "woody"
 

well that was interesting look .

Re: Ford Bronco "woody"
 

Following!

Re: Ford Bronco "woody"
 

I'm a woodworker, and one of my tools is a CNC (computer controlled) router. I decided to make a Ford Bronco body. I started with a floorboard and under-seat panel so that I could mount a charging jack and drive the thing as is. I've completed the front fenders, inner and outer, and a crossmember piece where the dash and hood will join. Working on the hood now.

Re: Ford Bronco "woody"
 

Nice. I should have known that was your build by the name of the thread. Nice work. I used to have a 5x10 Northwood router with a 30hp vac table. (I still have access to it whenever I want) it’s amazing the things one can make on it.


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Re: Ford Bronco "woody"
 

I'd love to see a photo of this router setup. Sounds cool.

Re: Ford Bronco "woody"
 

Nice work so far the wood work looks great!!! :thumbup: I built my jeep body 95% steel.

Re: Ford Bronco "woody"
 

It's a Carvewright system. Unlike most CNCs it moves boards in the X direction much like a planer so while compact itself it can handle long boards. To make the fenders I machined 12" wide 48" long sections and then glued them together.

Re: Ford Bronco "woody"
 

Nice! I considered doing a Jeep, as they are iconic and recognizable by nearly everyone. But the Bronco has nice details, especially the front, that will look cool when made from wood.