1st Cart: PCX-956 SHUTTLE

[mfinnegan]

holy crap your progress is amazing! you're making moves i hope to make one day lol.

looks really good man

[Andy4639]

Ya'll doing a good job on these old carts. They are good carts to work on and modify. I wish Hookem would post some pictures of the one I sold him a few years ago. He converted it over to gas. He put a lift on it and some nice upgrades.

[EzgoNewbie305]

Thanks guys. I think everyone is watching Andy4639’s work and getting inspired, or at least jealous. Lol. Mfinnegan, I started looking at motors and I might PlumQuick mine, I font have much room under the cart with the old rear and an the lift kit, I may have an inch clearance as is. Still have to research some more.

Here is another bit of progress. Since it sits high, there is a awkward looking area above the tires and I could see clear to the other side. I didn’t like the way it looked so I cut up some of the aluminum I had a filled out the wheel wells a bit. I know after I paint the wells black, they won’t be noticed, which is what I wanted. But I also didn’t want that area drawing negative attention either.

I also welded in some back supports for the controller area, and secured it and the battery’s tray bottom.

[EzgoNewbie305]

This being my first lithium DIY I’m not going to lie, it’s a bit intimidating. But luckily there is a lot of info on this site and I learned a lot. I mostly read MCJEFE’s post about building a Leaf Pack and got to work. Everything seems to be working, I still need to set the ZEVA parameters. But I left it unplugged for now until the I get my charger.

Ian at ZEVA says I can run the low voltage cutoff straight to the key switch and the high can for to a CAB/BUS charger. I will probably end up doing that.

[mfinnegan]

Originally Posted by EzgoNewbie305

This being my first lithium DIY I’m not going to lie, it’s a bit intimidating.

How's it all coming out?

[EzgoNewbie305]

Well, I’m starting back up on this project again. I’m recently got a Navitas 600 amp controller for a deal and I’m thinking I might want to upgrade the electrical to a Sepex system. I figure since I’m going to have to redo the motor anyways and I would like to use the regen braking with it. The navitas allows setting for rpm limits, regen braking, so that should help out those old mechanical brakes. Plus I don’t have to add a reverse contactor, less parts means less to break...hopefully.

[checkoutmyjunk]

Originally Posted by EzgoNewbie305

This cart came with hub caps and had one tire on a 4x4 pattern, the rest were the 5 lug style. I changed them all to a 4x4 pattern

Can you tell me what you did to change them to a 4x4 lug pattern?

[EzgoNewbie305]

Originally Posted by checkoutmyjunk

Can you tell me what you did to change them to a 4x4 lug pattern?

It’s not that bad. For the rear, I just found the same drum, with a 4 lug pattern.
The front, I had to change the whole hub assembly. I kept the spindle, because the axle and spindle is engineered opposite of the standard modern design. The rear axle on mine is 15/16th inch. On amazon it’s $60, the description says it’s “1 5/16” but it’s a typo. The front are hubs assemblies for Ezgo 1976-2001.5. They are $85.95 for the set. Hope that helps.

[checkoutmyjunk]

Originally Posted by EzgoNewbie305

It’s not that bad. For the rear, I just found the same drum, with a 4 lug pattern.
The front, I had to change the whole hub assembly. I kept the spindle, because the axle and spindle is engineered opposite of the standard modern design. The rear axle on mine is 15/16th inch. On amazon it’s $60, the description says it’s “1 5/16” but it’s a typo. The front are hubs assemblies for Ezgo 1976-2001.5. They are $85.95 for the set. Hope that helps.

Thank you! It helps me for sure.

I have the next generation 955E (2001) and once I get the basics sorted, I have a set of 22" "mudder" type tires on 4x4 wheels I'd like to put on it, and that means I need some lift too. If I can, I will copy your flip and lift blocks. living here in PA, I do not think 10" of lift + increased speed + 8 passengers + hilly off-road terrain will end in good results.

[EzgoNewbie305]

Originally Posted by checkoutmyjunk

Thank you! It helps me for sure.

I have the next generation 955E (2001) and once I get the basics sorted, I have a set of 22" "mudder" type tires on 4x4 wheels I'd like to put on it, and that means I need some lift too. If I can, I will copy your flip and lift blocks. living here in PA, I do not think 10" of lift + increased speed + 8 passengers + hilly off-road terrain will end in good results.

Copy all you want, I am looking at my motor options more and more and I will probably have to redesign my rear end lift. There isn’t much room for a bigger motor, I’m weighing my options and skills at this point. But with a smaller lift, maybe just blocks where the springs attach to the frame would be better, or even an axle flip might fit your needs.