EZGO Marathon coming back from the dead

[Hi Proof Products]

Im new to carts so I’ll admit I have a lot to learn. Suggestions are always welcome criticism I’ll accept. Recently came across a 1988 EZGO Marathon dirt cheap and since we are sitting on 6 acres figured why not. My intentions are to strip all of the electrics out which I have already done. It was indeed a mess but at least I know the cart runs. I stripped it down to the frame, I’ll attach a picture.
I want to first get the cart running. Been doing some homework and think I might settle for a new key switch, ALLTRAX controller, a Curtis pot for the throttle, a heavy duty solenoid, and a electric reversing contactor. The cart came to me with 3 new 12 volt deep cycle batteries and my intentions are to go straight to 48 volts but I’ll need advice on batteries.
While I’m waiting on parts there’s a 5” lift kit ready to go on the cart.

[Hi Proof Products]

Stripped cart

[Hi Proof Products]

The battery supports were pretty much eaten away through the years by spilled battery acid so the plasma cutter quickly eliminated them. I’ll be making new from some 1” angle that we picked up today. The black that you see is all primer that I used after hitting the cart with phosphoric acid to convert the rust.

[B Swan]

So far . . .

[Sir Nuke]

as far as the batteries go....TRASH this 12v......do not go with 4 12v's...….you will want to either go with 6-8v's or 8-6v's.....depending on what you want to do with the cart. personally most go with 6-8v's as you can easily get 20+ miles out of a charge....depending on the terrain.

[Hi Proof Products]

Today we lifted the cart 5”. Had to order leaf spring rubber bushings as they were all shot as well as the U-bolts for the rear axle that snapped when removing them.

[Hi Proof Products]

Originally Posted by Sir Nuke

as far as the batteries go....TRASH this 12v......do not go with 4 12v's...….you will want to either go with 6-8v's or 8-6v's.....depending on what you want to do with the cart. personally most go with 6-8v's as you can easily get 20+ miles out of a charge....depending on the terrain.

Thanks for the advice. By the time I figure the cost of new batteries and a new charger might it be worthwhile to consider lithium ion with a built in BMS and charger?

[Hi Proof Products]

BTW Sir Nuke how do you like your ALLTRAX Controller? Are you running a reversing contactor with it?

[Hi Proof Products]

Well I got the rubber bushings installed in the rear leaf springs which really tightened things up in the back. Turned my attention to some slop I had in the steering. Turns out after inspection that both bushings in the vertical idler are trash. They appear to be bronze oiliness type bearings and because they were most likely never greased wore the shaft. I am going to reverse the shaft so the worn section no longer rides within the flange bearings. All I need do is drill a new hoke for the cotter pin located at the bottom I pulled the rack apart to check the reduction gear but that seems to be fine. I did get a bit carried away and damaged the ball joint that connects to the lower idler.

[Hi Proof Products]

I visited a local shop that sold carts and when I saw the 23” tires couldn’t resist.