Buggies Gone Wild Golf Cart Forum

Buggies Gone Wild Golf Cart Forum (http://www.buggiesgonewild.com/)
-   All things Lithium (http://www.buggiesgonewild.com/all-things-lithium/)
-   -   Club Car DS lithium upgrade and 4-Link (http://www.buggiesgonewild.com/all-things-lithium/145679-club-car-ds-lithium-upgrade-4-link.html)

NCPW 08-31-2018 01:31 PM

Club Car DS lithium upgrade and 4-Link
 
2 Attachment(s)
This will be a VERY slow build compared to the ones I read here daily. Hope to have it finished up within a few weeks but I'm not in a rush and not on a timeline so I plan on doing it right the first time...hopefully. :lol: Plus I plan on buttoning up a few things like wiring to make it more aesthetically pleasing, cleaning/painting the frame again and few other things.

I upgraded the cart a couple of years ago from a 36V resistor cart to a solid state drive system and 48V as well as some cosmetics more suited towards hunting and running through the woods (which is what the cart does most of the time). So this will be Ver. 2.0 when I'm done. :mrgreen:

First thing on the list is gathering everything needed to do a lithium conversion. I've been reading/studying on converting to lithium since reading through SportCoupe's http://www.buggiesgonewild.com/elect...txt-build.html a few years ago, not to mention every other lithium build the great members here have posted since. I have learned a great deal from a lot of you and asked my questions via PMs, e-mails and phone conversations. So thank you to those members and one in particular who has been a great asset to me and this forum is very lucky to have him as a member. He knows who he is and I won't mention his name because I don't want him to get bombarded with questions but if he chooses to speak up, that's his decision.

Second thing is ditching the HD rear leaf springs for a better ride using a 4-link set up. I've read though countless threads on here as well as off-roading forums and watched many youtube videos (makes me a professional now, right? :lhmo:) to decide I want to go with a triangulated set-up. I think this will make it as easy as possible, avoid having to use a panhard bar and get around/clear the motor without issue hopefully. I'm not going for extreme articulation but for a more comfortable ride.

For the lithium conversion I have everything in my possession right now except the BMS and display from Zeva. They were out of stock when I ordered earlier this month but Ian expected to be able to ship my order out anytime between now to the beginning of September. In the meantime I'll do what I can with what I have. For the 4-link I have all my tubes, hiems, spacers, jam nuts, shock mount tabs, angle steel to mount everything, wheel spacers and coilovers.

After removing all current electronics and taking many pictures to make sure I wire everything back up correctly.
Attachment 174665

Here I cut out and ground down the necessary aluminum angle to get the diamond plate to fit nicely. This is a dry fit and nothing is secured down yet because I plan on sanding and painting first.
Attachment 174666

More to follow

bronsonj 08-31-2018 07:45 PM

Re: Club Car DS lithium upgrade and 4-Link
 
subscribed.

Bluetick 08-31-2018 09:51 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Can't wait to see more very interested !

NCPW 09-05-2018 11:24 AM

Re: Club Car DS lithium upgrade and 4-Link
 
4 Attachment(s)
I decided to move my package from EV Battery Center inside to assemble what I can and inspect the Leaf modules.

All cells measured 3.94-3.95V and visually look flawless. Not even a scratch on the metal casing.

EV Battery Center did a great job packing the modules in a ton of packing peanuts and Styrofoam to keep everything safe during transport.
Attachment 174855

After cleaning all the packing off and inspecting the modules. No bloating noted and all cells measured within .01V.
Attachment 174856

Pack assembled in correct orientation with aluminum plates. Just waiting on BMS to arrive now. I covered the terminals with painter's tape for extra caution while waiting on final assembly and install.
Attachment 174857
Attachment 174858

I finished up grinding, sanding and cleaning the battery tray and will put another coat of black paint to dress it back up hopefully later this week. Then the diamond plate will be secured in place.

I just got confirmation this morning from DHL my ZEVA BMS16V2, EVMS monitor V3, temperature probe and CANbus wiring will be delivered Friday. :thumbup:

swsawyer@reagan.com 09-05-2018 09:00 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Subscribed too!! I plan on executing a lithium upgrade, one day, but plan on taking it slow and steady like NCPW. My only “complaint” is following and reading what everyone else is doing tests my patience and resolve to take things slow. Given the fact that I have never been blessed with an abundance of patience, makes things challenging. I guess it is a good thing that Household 6 keeps my checkbook in her purse. LOL.

E36Racer 09-05-2018 09:12 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Some nice plates youíve got there....

Roxyflash 09-05-2018 09:35 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Looks like a low voltage pack 7x4 28 volts am i missing something

NoleFan4Ever 09-05-2018 09:41 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by Roxyflash (Post 1538446)
Looks like a low voltage pack 7x4 28 volts am i missing something

Lol! Nissan Leaf's. 2 in parralel and 2 in series. 7 modules = 14 cells. 4.2v max/cell = 58.8 volts...:thumbup:

And to be safe, we run 4.17v/cell (58.4v) to protect the cells from high charge damage...

NCPW 09-05-2018 09:57 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by E36Racer (Post 1538435)
Some nice plates youíve got there....

:thumbup:

Bet you'd never guess where they came from :lol:

NCPW 09-05-2018 09:58 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by Roxyflash (Post 1538446)
Looks like a low voltage pack 7x4 28 volts am i missing something

Like Nole said, big bang in a little package.

E36Racer 09-05-2018 10:00 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by NCPW (Post 1538466)
:thumbup:



Bet you'd never guess where they came from :lol:



[emoji6]

NCPW 09-05-2018 10:08 PM

Re: Club Car DS lithium upgrade and 4-Link
 
1 Attachment(s)
Repainted the battery tray tonight with a few coats of Rustoleum enamel and cut 3 peices of flat 1/8" aluminium. I'll rivet those in place under each of the aluminum plates for extra support just in case. You know, like a belt for suspenders. :mrgreen:
Attachment 174874

NoleFan4Ever 09-05-2018 10:15 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by NCPW (Post 1538466)
:thumbup: Bet you'd never guess where they came from :lol:

Quote:

Originally Posted by E36Racer (Post 1538470)
[emoji6]

Oh wait... Was it.... Or maybe it was.....Yeah, it had to be..... I guess it could be.... Yep, talked to him after you called.... Best decision you could have made! :thumbup:

E36Racer 09-05-2018 10:29 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Iím curious to see what you do for the 4 link. Iíve been considering something along those lines myself. I have a factory track bar, which helps. But I havenít convinced myself on a plan of attack. I also want to come up with a front sway bar. But finding one only 20-30Ē wide is near impossible.

NCPW 09-06-2018 06:13 AM

Re: Club Car DS lithium upgrade and 4-Link
 
The 4 link's going to be a trial and error kinda of deal I think, unless the plan in my head is absolutely perfect (with my track record, probably not:wink:). I've measured many times and think it'll work. We'll just have to find out.

The plan's to have parallel bars below the axle and triangulated bars above with my coilovers spaced as far apart as possible to give the most stability.

NCPW 09-06-2018 06:24 AM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by NoleFan4Ever (Post 1538481)
Oh wait... Was it.... Or maybe it was.....Yeah, it had to be..... I guess it could be.... Yep, talked to him after you called.... Best decision you could have made! :thumbup:

That's right! :thumbup:

I got a feeling you're not going to like my top cover too much though:mrgreen:

fsu1tm 09-06-2018 06:41 AM

Re: Club Car DS lithium upgrade and 4-Link
 
NCPW. How did those plates fit? I think your "unmentioned person" used the measurements from my build. I used foil tape to close up the gaps not filled by the plates. As I can attest from this past weekend, it kept the water out nicely. Can't wait to follow your progress. I was too chicken to try assembly on my own.

NoleFan4Ever 09-06-2018 07:41 AM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by NCPW (Post 1538560)
That's right! :thumbup:

I got a feeling you're not going to like my top cover too much though:mrgreen:

NO!!!! :help:

NoleFan4Ever 09-06-2018 07:45 AM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by fsu1tm (Post 1538561)
NCPW. How did those plates fit?

Hank showed me your design and templates - professional all the way!! (And I wouldn't expect anything less from an FSU guy...) :thumbup:

NCPW 09-06-2018 08:55 AM

Re: Club Car DS lithium upgrade and 4-Link
 
1 Attachment(s)
Quote:

Originally Posted by fsu1tm (Post 1538561)
NCPW. How did those plates fit? I think your "unmentioned person" used the measurements from my build. I used foil tape to close up the gaps not filled by the plates. As I can attest from this past weekend, it kept the water out nicely. Can't wait to follow your progress. I was too chicken to try assembly on my own.

Hank, I took your measurements and they were spot on with about a 1/8-3/16" wiggle room, which was perfect. :thumbup: You did an awesome job with your measurements.

The back plate was great side to side but the only difference between your '90 and my '99 DS that I didn't realize at the time was how the front back supports mount. I have a curve the prevented the back plate from sitting flush against the supports. I looked at yours and the back support mounts don't have the same curve in them that mine do. It's there to give the back of my bench seat extra support so I didn't feel comfortable cutting them like yours and just depending on the body to support the weight of me and a passenger.
Attachment 174889


I hated to do it because he did such an awesome job fabbing the back plate, but I had to cut about an inch off of the plate from each side that fits down between the 2 I-beams of the frame to get it to fit properly. It turned out fine using my jigsaw with a DeWalt metal blade and taking my time.

The foil tape is a great idea and I'll use that to enclose all the gaps I can once I'm done.

fsu1tm 09-06-2018 01:49 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Your seat back supports are a little different. Mine don't have the kick-out. I had him put a 17 degree back angle on the top and the back plate tucked in right behind the supports. Bolts then went through seat brackets and back plate.

Next time you need to cut plate aluminum, use a circular saw and a carbide tipped blade. It'll cut like butter. Or course a straight edge is recommended as well as going slow. Makes a heck of a noise but as smooth as can get. :thumbup:

I'll be following the rest of your build. You're going to love the weight loss and increased run time. My speed also increased significantly but I went from 36V.

NCPW 09-22-2018 10:19 PM

Re: Club Car DS lithium upgrade and 4-Link
 
3 Attachment(s)
Started on the suspension today because I'd love to have that fabbed up and installed before putting the pack in the cart and wiring it up.

I'll be using some 1/8" angle steel to make brackets to weld my shock mount tabs to. Then I'll bolt the steel to the frame since I don't have the ability to weld aluminum.

I cut a 5" length and a 6" length to weld into a "L" shape.
Attachment 175605

The vertical 6" section will be bolted to the frame. The 5" horizontal section will have the shock tabs welded to it to secure the top of the coilover and I'll weld tabs as far to the outside of the axle as possible to secure the bottom of the coilover.
Attachment 175606

Added a small gusset for a little extra strength. This is how it'll be secured to the frame when finished.
Attachment 175607

NCPW 09-26-2018 03:08 PM

Re: Club Car DS lithium upgrade and 4-Link
 
1 Attachment(s)
Extended the temp sensor last night using 22ga wire. 22ga is very small so you can image how small this temp sensor from Zeva is. They include about 2" of wire from the sensor for you to add your length.

Attachment 175774

I placed mine between the 3rd and 4th batteries with a dab of silicone.

NCPW 09-26-2018 03:16 PM

Re: Club Car DS lithium upgrade and 4-Link
 
3 Attachment(s)
Started removing the rear leafs, block lift and shocks and cleaned up the left side in prep for welding the hiem mounting tabs.

Attachment 175775


Had to remove the motor to keep the axle from twisting on me. Slid off like butter thanks to some copper antisieze I applied to the trans shaft when I installed this motor. I forgot how heavy it is.

The motor looks really clean to me. Anybody see anything in the windings I should be concerned with?

Attachment 175776
Attachment 175777

NoleFan4Ever 09-26-2018 03:18 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by NCPW (Post 1544306)
-snip-
Anybody see anything in the windings I should be concerned with?

That looks perfect! :thumbup:

NCPW 09-26-2018 03:27 PM

Re: Club Car DS lithium upgrade and 4-Link
 
:thumbup: Thanks Nole!

NCPW 10-01-2018 09:07 AM

Re: Club Car DS lithium upgrade and 4-Link
 
4 Attachment(s)
Ran all the wires from the tap harness to the BMS and mounted the BMS to the side plate using double sided adhesive tape. I solder tinned all the wires from each cell before placing them in the Molex connector and screwing them down to prevent any short circuit from a stray wire after stripping. Afterwards, when everything was how I wanted, I went back and placed a dab of blue thread locker on each bolt for peace of mind. Getting there, slowly but surely.

Attachment 175982

Attachment 175983

Attachment 175984

Attachment 175985

Edit: sorry, not sure why my pics came out sideways that time.

BBBHC 10-01-2018 09:30 AM

Re: Club Car DS lithium upgrade and 4-Link
 
I've noticed anytime I post a picture that is bigger than 600 x 600 pixels, they show up sideways. I make a "copy" of the picture I want to post, go to edit and resize the pixels accordingly and they show up correctly

NoleFan4Ever 10-01-2018 05:07 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Any type of resizing will wipe out the embedded code from Iphones and let the picture be straight. (Sergio passed that on to me a while back)

NCPW 10-01-2018 05:10 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Im using Android.

I've tried rotating the picture 360 degrees to see if that works to no avail. So I've been emailing the pics to myself, saving the download and renaming them which had worked thus far until now. :?

NoleFan4Ever 10-01-2018 05:12 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Looking great NCPW! And I already had to reland mine in the Molex twice due to contact issues.... :thumbup:

BMS went WILD!!

NCPW 10-16-2018 03:39 PM

Re: Club Car DS lithium upgrade and 4-Link
 
1 Attachment(s)
So I've decided to hold off on the 4 link for right now. I do plan on finishing it up and will post it in this thread when I do. With 2 little ones 4 years and younger, long days at work and chores around the house never ending,
I can't seem to find the time to work on the cart like I'd like to.

So I'll finish up the lithium, get back to riding and eventually finish up the rear suspension.

Mounting everything I can to the rear plate to free up as much space as possible on the floor. I finished mounting the DC-DC converter, charger and fuse panel to the driver's side of the plate and wired everything except the SW202 reversing contact. Just forgot to take a pic of it.
Attachment 176750

Connected my Zeva display using the CAN cable and looks like all of bms wiring was done right there 1st time. :mrgreen:

More to follow.

UncleJerm76 10-16-2018 03:46 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by NCPW (Post 1550603)
So I've decided to hold off on the 4 link for right now. I do plan on finishing it up and will post it in this thread when I do. With 2 little ones 4 years and younger, long days at work and chores around the house never ending,

I can't seem to find the time to work on the cart like I'd like too.


This is the #1 reason Iím following your post [emoji23]. I hear ya tho, Iím in the exact same boat, 2 youngíns 1 & 3 and the house and yard work wait for no man.

Itís been a struggle finding the room for all my triangulated 4 link bars and coilovers. I never realized just how little room I have after the 2-speed Axle and big D&D motor upgrades. [scratching head]

I keep throwing the leafs back on so I can ride the kiddos around and then come back to it later [emoji23]. Look forward to your updates, keep it up!


Sent from my iPhone using Tapatalk

NCPW 10-16-2018 04:20 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Yeah, I was in the process of grinding/sanding the axle mount tabs Saturday, in between having my 4 year old beg me to push her and the other neighborhood kids on the swing set,it ended up taking me a good hour to get 2 just the way I wanted. I've got about 10 more to go and I thought, "Man, I don't even have the battery pack installed yet :?"

So, I figured I have all the measurements I need and know how I'm going to install the 4 link and I can always go back and install the suspension with all the electrical stuff connected. So why not install the battery pack and everything needed to get it back running and eventually jack up the rear end and weld/bolt on everything for the rear when I get time. Plus it's deer season. :mrgreen:

NoleFan4Ever 10-16-2018 04:26 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Looking SWEET!

NCPW 10-17-2018 09:05 AM

Re: Club Car DS lithium upgrade and 4-Link
 
2 Attachment(s)
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. Wiring will be cleaned up and better secured once everything is tightened down.
Attachment 176785

Attachment 176786

Some might be wondering why I have the Zeva display mounted to the pack instead of the dash. Well it's fancy and all and gives me the ability to control BMS operation, but it wouldn't serve me any better than my DVM that's already mounted there. I'll know once I get to around 52V or so it's time to turn around and head to the house.

BBBHC 10-17-2018 11:00 AM

Re: Club Car DS lithium upgrade and 4-Link
 
Looking good! Thanks for posting pictures! I'm doing a similar build and like seeing how others are doing theirs to get ideas

NCPW 10-17-2018 11:39 AM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by BBBHC (Post 1550911)
Looking good! Thanks for posting pictures! I'm doing a similar build and like seeing how others are doing theirs to get ideas

That's what this kind of threads are for. To give each other ideas.

You having a double pack will be kind of difficult to mount without separating the pack. Unless the gas cart that you converted from has a different layout than the electric carts. If you wanted to keep the pack all together, I guess you could mount it sideways in the center between the frame rails. But you wouldn't be able to utilize a back plate the way I have.

BBBHC 10-17-2018 11:50 AM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by NCPW (Post 1550933)
That's what this kind of threads are for. To give each other ideas.

Absolutely! I'll be starting a build thread for mine soon.

PingEye3 10-17-2018 12:38 PM

Re: Club Car DS lithium upgrade and 4-Link
 
Quote:

Originally Posted by NCPW (Post 1550853)
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. Wiring will be cleaned up and better secured once everything is tightened down.
Attachment 176785

Attachment 176786

Some might be wondering why I have the Zeva display mounted to the pack instead of the dash. Well it's fancy and all and gives me the ability to control BMS operation, but it wouldn't serve me any better than my DVM that's already mounted there. I'll know once I get to around 52V or so it's time to turn around and head to the house.

Everything is fitting very nicely on the back plate. Looks great. :thumbup:


All times are GMT -5. The time now is 03:58 PM.

Powered by vBulletin® Version 3.8.6
Copyright ©2000 - 2020, Jelsoft Enterprises Ltd.
Content Relevant URLs by vBSEO ©2011, Crawlability, Inc.
This Website and forum is the property of Buggiesgonewild.com. No material may be taken or duplicated in part or full without prior written consent of the owners of buggiesgonewild.com. © 2006-2017 Buggiesgonewild.com. All rights reserved.