Gornoman's Z06 tribute...Quick and Quiet!

[gornoman]

From humble beginnings and a willingness to spend a winter being productive:

Well actually, it has taken a few years to get this far because it continues as a work in progress





There are a few mores ideas being worked on, primarily an upgrade to 48v, and next year perhaps a 2/speed motor conversion.

Thanx for looking.

[BAMAWELLS]

Thanks for the pictures..... Also if you ever do the convertion to 48 Volts you will never go back to a 36 Volt Cart. You will also wish you had done that project sooner....

[NO NO NO E-Z-GO!]

I like the Z06 2.0 HP decal. I think it says 2.0 anyway. It never ceases to amaze me how clean you keep the cart. It looks like it just rolled off the assembly line in every picture I've ever seen, but we all know you ride it. Great job! Keep up the good work.

[gornoman]

Thanx fellas!

The 48v upgrade has been OK'd by the Boss, so it's not a matter of IF, it's a matter of WHEN. The campground opens in 1 week. First order of business:

A complete Detail Job (6 months without a wash - ouch )
LED Tail lights (Xmas gift from my daughter)
Battery checks and fills, cable inspections
Chassis lube, tire pressures
Extended tour of the campground
Draw/photgraph current schematic of 36v system to help plan the 48v install

And No-No, I keep it that clean to give the neighbors something to laugh about. Also, it's much easier to maintain and fiddle-with a nice clean cart.

[NO NO NO E-Z-GO!]

I agree 110%, gorno! I'd much rather mess with a clean cart than a dirty, greasy one. I like being able to reach down in my engine compartment if I drop something and bring my arm back out clean, not with a big, black smear all over my arm. When I grease the front end, I wipe off ANY excess grease to ensure I don't get it all over my when I need to do something. You probably have a harder time getting to some of your grease zerks though; I noticed on the TXT I have, the one on the steering box and that tie-rod are little PsITA to get to to work on, most of the others are straightforward and easy.

[Tom Fazio]

if everyone was like gorno than those of us who spend our time working on the carts and keeping them running would be sitting with the maytag man playing cards or shooting pool..........its that lack of any basic maintence that gives us a lot of our work......so i hope whatever it is that gorno has isn,t catchy..........................................

[NO NO NO E-Z-GO!]

When I start working on them at a campground this summer, I'm going to have a lot of \"fun\" telling people how \"...a clean cart is a happy cart...\"

[Tom Fazio]

arron, i take it this will be your 1st year repairing at a campground oh boy your in for some fun.,.......try to get in the habit of working on them at night you,ll get a lot more done with a lot less interuptions........nice and peaceful also, if i can help in any way give a shout and i,d be happy to help if i can, also try and keep the basics in stock for now, sparkplugs, filters, air oil and fuel......a few fuelpump rebuild kits maybe a carb rebuild kit, ;lots of 12 to 16 ghage wire and assorted ends and connecto, micro switches.......a few solenoids 12, 36 and 48 .....a few starter and drive belts a set of starter brushes.........sounds like a lot but its not ..........carb cleaner, brake cleen....a decent air compressor, a good shed to keep your tools and supplies in........elec. tape and duct tape...................like i said if i can help just give a shout........remember you don,t work for free and always stand behind your work......your work not the customers or one of their buddies.................good luck my friend i think you,ll enjoy this..........................................

[NO NO NO E-Z-GO!]

I'm not sure about it yet, and it's not what I had first anticipated, but a guy came to look at the camouflage Club Car I have for sale, and he told me that the campground he goes to always has someone looking for someone to repair their cart. I thought I could just go down there each weekend and look into things for people. Plus they have golf cart races there, so I could go and whoop up on some EZGO and Yamaha hiny! LOL

Thanks for the tips, and you'll be the first I contact if I ever need anything. You seem to always know your stuff right off the top of your head. GREAT WORK!!!!! After working on thousands so many times, I guess it comes natural to a point.

[Tom Fazio]

i have a long way to go but the fact that i get to see every brand of cart helps out, gas or elec. i,ll PM you tomorrow...........go for it............i went into this cold.....never touched a cart in my life till 4 years ago or so .....i have come a way but i,m no where near where i want to be but i,ll just keep plugging away at it...........it gets easier every time out and all of what i do is referral or repeat business so one thing i know is even thought i don,t know everything i know enough that people trust i,ll treat them right and do whatever it takes to get their cart going for them

[gornoman]

..........its that lack of any basic maintence that gives us a lot of our work......so i hope whatever it is that gorno has isn,t catchy..........................................

So far I have only been able to infect 2 other cart owners in our enire campground (400+ carts). When the 3 of us get together for some brats and beers the front yard looks like a car show!

The "dirty" carts have to park around back

[gornoman]

Well, I just couldn't leave it alone. I did my research (Thanx to Andy, Nate, Caddiemaster, and quite a few others) and paid attention, and made the jump to 48 VOLTS. The controller was already rated for the voltage, and the rest was easy.

First, I visited Sam's club for 2 fresh 6v cells and a smart 12v charger. Charged the 2 new cells together as a 12v unit:

Placed one cell under the driver's seat and the other out back in the passenger side bagwell. Needed to make some new cables with the torch and the solder pellets. I improvised a safe work area in my shed at the campground:


Once the wiring was complete I took it out for it's first run. I am moving flat out FTTF around this curve, and as you can see, she is flying!

The torque gain was quite impressive


I am VERY pleased with the performance gains. Torque is up, top speed is up. Can't ask for more than that!

2 new batteries $130
New 12v charger $50
3 new 4g cables $0 (leftover from previous project)
Ability to outrun any cart in camp - PRICELESS

[NO NO NO E-Z-GO!]

Glad everything worked out well for you Gorno! It looks like you accomplished the project on a great budget, and got great gains out of it. And it really looks like you're leaning a LOT in that turn, am I going to have to take the cart away from you, Mr.?
Dare I ask what is on your jacket in that one picture?

[gornoman]

The lean is with HD springs and fresh shocks all around. That cart was FLYING!!!!

Stains on my clothes are from Alien encounters. I don't know where they come from (the stains!) but my wife will tell you that I NEVER put on old clothes to do ANY work.

I think she is just Laundry Challenged!

[gornoman]

Here is the full story:

The cart was a 36v Fleet style with an Alltrax AXE 400amp Programmable controler, as well as 4g Welding Cables. All else on the cart was stock electricly, except for extra 12v goodies. The Alltrax controller was allready rated for 48v.

I added 2-6v batteries wired in series for a total of 48vdc, one under the drivers side, and one in the passenger's bagwell:




The white wire from the cart charge receptacle was moved from it's original position at the Main Pack Positive upstream 2 batteries to it's new position on battery 3 positive terminal. Now the Powerwise charger only \"sees\" 36vdc and can still be used as normal. The additional charger is hooked up across batteries 1 and 2 in the pack, and as such only \"sees\" 12vdc. Both chargers are running simultaneously, no wires have been disconnected.


All of the control wiring still only \"sees\" 36v (this reading is across the small posts of the stock solenoid, key on, cart in gear, light pressure on the go pedal to activte solenoid circuit):

And the main pack now totals 48vdc (and then some!):

This pack voltage was after running the cart Friday night and all day Saturday, just as I was preparing to leave Sunday. I don't think range will be an issue. I saw 53.9vdc last weekend after a full charge cycle.

This is a VERY EASY upgrade if you have the proper controller already.