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Unread 10-17-2018, 01:05 PM   #41
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Default Re: Club Car DS lithium upgrade and 4-Link

Thanks Gary!

The only other thing I had to do was bend the top corners back 45 degrees so the body would sit flush. The edges of the corners stopped the body by a half inch.

Also, after test fitting the body, I found out the 2 areas swooping forward coming off the seat back supports I mentioned in a prior post, that kept the back plate from sitting in place do not support the bench. I could've just cut those tabs off and avoided trimming the back plate at all.
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Unread 10-17-2018, 01:25 PM   #42
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Default Re: Club Car DS lithium upgrade and 4-Link

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A couple of more pics of how I've laid everything out to keep as much space as possible free on the bottom for storage or in case I ever need to expand the battery pack. -snip-
NCPW, hope you do not mind but I was throwing these in just as a comparison of our two similar systems but different design thoughts (Note- ACC affiliates!!). I was thinking access capability and design conflicts once the body was reinstalled. (And I hid my personality switch as an anti-theft device so when enabled, the solenoid will click but the cart not go anywhere )

I like what you are doing, it looks great and VERY professional!

GC Upgrade2 8-2018.jpg

GC Upgrade5 8-2018.jpg
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Unread 10-17-2018, 02:11 PM   #43
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Default Re: Club Car DS lithium upgrade and 4-Link

Very neat and clean Nole I like it and don't mind a bit.

ACC all they way brother!
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Unread 10-17-2018, 02:21 PM   #44
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Default Re: Club Car DS lithium upgrade and 4-Link

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...ACC all they way brother!
Unless you're a Louisville fan, like me. Fun times...
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Unread 10-17-2018, 02:25 PM   #45
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Default Re: Club Car DS lithium upgrade and 4-Link

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Unless you're a Louisville fan, like me. Fun times...
Football and baseball shouldn't be a big deal in that regard, but basketball's a tougher division for them. But the ACC is tough for all the schools in the ACC when in comes to basketball.
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Unread 10-17-2018, 08:56 PM   #46
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Default Re: Club Car DS lithium upgrade and 4-Link

Nothing to add, except, SEC all the way!

(Even though College Station is a bit of a stretch calling it South East)
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Unread 10-19-2018, 10:39 AM   #47
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Default Re: Club Car DS lithium upgrade and 4-Link

Spent just a few minutes last night running the 14 gauge wires for my reversing contactor to where the fwd/rev toggle switch will be.

I also checked that the charger is working before I cut/splice the AC cable to the new male receptacle I'll install where the charging port was located.

PackCharging.jpg

BMSDisplay.jpg

Question for those of you who are using the Zeva BMS and Leaf modules: Did you set the total pack ah to 55 or 60?

I set mine to 55ah and see that my percentage bar read 100% when my pack was only at 56V and each cell 4.0xx volts. I have the max charge voltage set to 58V for the pack and each cell to 4.17V with the balance to initiate at 4.15V.
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Unread 10-20-2018, 05:44 PM   #48
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Default Re: Club Car DS lithium upgrade and 4-Link

Last night I let the charger run until it shutoff to test the HV relay. It did shut off but at 56.2V instead of the 58.38V I wanted it to. I'll have to figure that one out.

I made all the high voltage cables also then took it for a test drive.

First thing I noticed is the lithium batteries are more responsive that the FLA. I tested the power out on a good hill that I used to get up to 18mph on with the FLA. I got up to 21mph and quick with the lithium pack and reduced weight.

I'll finishing buttoning everything back up and call this part of the project complete. I'll post final pics once done.
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Unread 10-20-2018, 06:17 PM   #49
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Default Re: Club Car DS lithium upgrade and 4-Link

Nice!! I'll look forward to seeing the final pictures!
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Unread 10-20-2018, 08:22 PM   #50
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Default Re: Club Car DS lithium upgrade and 4-Link

Great job Pal!
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