GX390 + 2003 Club Car DS Electric = ?

STSClays.com · 03-10-2013, 04:18 PM

I have a very clean cart im planning on doing this swap on. My plan is to make a cradle that mounts to the rear axle and has a linked pivot in the front. The ability to do this is well within my fab skills but I have a few questions that im sure some of you have experience with.

1) What is the best way to attach a sprocket on to the rear axle? If anyone knows the correct sprocket to order (Shaft Diameter/Spline Count/Type of Spline) I would appreciate the assistance.

2) What amount of Suspension Lift and Wheel/Tire Sizes are recommended to maintain some Ground Clearance?

STSClays.com · 03-10-2013, 04:18 PM

Any other suggestions welcomed as well!

sho305 · 03-10-2013, 05:03 PM

Depends on what way you do it, you will have no reverse with an electric axle. You need a transmission of some kind like the CVT on a cart. If you use a gokart clutch you get one gear it is not ideal. You can run a jackshaft to put a secondary on and change the gearing to the elec trans via chain. If I were you I would price out an ezgo rear with the posi locker. Depends on what you expect from the cart I guess.

Far as a lift I would recommend you get one that fits 22s at a minimum, though 20s do work. There are a lot more tires available for 22s. Get an ATV tire they don't get punctures like 2 ply can. You can go larger like 25s, more cost and more gearing and need a larger lift. The LT (long travel) lifts are nicer offroad and ride nicer, some fit larger than 22 tires. Ones that come with new shocks usually are significantly better as the stock shocks/springs are limited in what additional travel they can handle well. The spindle lifts look cool but don't usually make the cart ride/handle much better, there is a reason atv have double arm fronts. The larger tires will help it ride nicer over stock even with a budget lift, just because they are larger.

STSClays.com · 03-10-2013, 05:08 PM

My plans include a Comet CVT and Forward/Reverse Trans.

sho305 · 03-10-2013, 06:49 PM

We are here to help lol. I say the ezgo rear because with the clone I wish I had posi at times but I have no idea what the cost on them is compared to others. The ezgo cradle is very simple and similar to what I would make for any cart if I were fabricating one. Though I would use coilovers and not leaf springs.

Once you get a rear you can get a secondary to fit, then a primary for the clone. Some (or all?) CC used a 1" belt so watch out for that, most ezgo and yamaha use 1 3/16 which is somewhat standard and much more available in various sizes.

If you fab a cradle you should check out some of the builds of 3 link and other rears that really help the cart, though some are pretty serious offroad carts.

STSClays.com · 03-10-2013, 07:25 PM

Quote:

Originally Posted by sho305

We are here to help lol. I say the ezgo rear because with the clone I wish I had posi at times but I have no idea what the cost on them is compared to others. The ezgo cradle is very simple and similar to what I would make for any cart if I were fabricating one. Though I would use coilovers and not leaf springs.

Once you get a rear you can get a secondary to fit, then a primary for the clone. Some (or all?) CC used a 1" belt so watch out for that, most ezgo and yamaha use 1 3/16 which is somewhat standard and much more available in various sizes.

If you fab a cradle you should check out some of the builds of 3 link and other rears that really help the cart, though some are pretty serious offroad carts.

I agree it would be nice to find a Poi-Rear axle but I haven't even found a gas rear axle for sale anywhere.

STSClays.com · 03-14-2013, 09:48 PM

Well, I cut out the Battery Supports today and will get to work installing a Lift Kit tomorrow if it arrives. I will then begin work on an engine cradle.

I just wished there was a good source for used parts for these things. My friend has a DS cart that has an engine cradle that mounts to the rear Leaf Spring Pads. He has no idea where it came from as that is the way he got the cart but I will just build mine similar to his.

Joe

tjb406 · 03-15-2013, 08:38 PM

check out my build thread there are a couple pics of the cradle i built in it ,it bolts to the six bolt holes on the rear axle. and goes forward to the angle at the rear of where the brake braket welds on. bought a club car basket case under members rides.

sho305 · 03-15-2013, 08:43 PM

If you look in the build and offroad threads there are plenty of photos of that stuff. Also look at the ezgo cradles for sale (new ones aftermarket). Only thing you really need to consider is how you support the axle, they usually need to mount where the stock cradle did so you don't break an axle tube or something like that due to poor support. And that depends on what rear you get.

STSClays.com · 03-17-2013, 08:50 PM

Well, I decided that instead of buying a transmission for reverse I would just buy this instead.

surplus center in lincoln, ne has a reversing rearend for $ 329.00 + shipping....

www.surpluscenter.com

part # 13-1468

It looks like a nice unit and will be super simple to build an engine cradle off of. The spring perches are welded onto the axle on top so that will make for an easy conversion if the spacing is correct.

03-10-2013, 04:18 PM	#1
STSClays.com Getting Wild Join Date: Mar 2013 Posts: 77	GX390 + 2003 Club Car DS Electric = ? I have a very clean cart im planning on doing this swap on. My plan is to make a cradle that mounts to the rear axle and has a linked pivot in the front. The ability to do this is well within my fab skills but I have a few questions that im sure some of you have experience with. 1) What is the best way to attach a sprocket on to the rear axle? If anyone knows the correct sprocket to order (Shaft Diameter/Spline Count/Type of Spline) I would appreciate the assistance. 2) What amount of Suspension Lift and Wheel/Tire Sizes are recommended to maintain some Ground Clearance?
STSClays.com Getting Wild Join Date: Mar 2013 Posts: 77

03-10-2013, 04:18 PM	#2
STSClays.com Getting Wild Join Date: Mar 2013 Posts: 77	Re: GX390 + 2003 Club Car DS Electric = ? Any other suggestions welcomed as well!
STSClays.com Getting Wild Join Date: Mar 2013 Posts: 77

03-10-2013, 05:03 PM	#3
sho305 Vegas modded 420 Join Date: Jun 2009 Location: West MI Posts: 15,443	Re: GX390 + 2003 Club Car DS Electric = ? Depends on what way you do it, you will have no reverse with an electric axle. You need a transmission of some kind like the CVT on a cart. If you use a gokart clutch you get one gear it is not ideal. You can run a jackshaft to put a secondary on and change the gearing to the elec trans via chain. If I were you I would price out an ezgo rear with the posi locker. Depends on what you expect from the cart I guess. Far as a lift I would recommend you get one that fits 22s at a minimum, though 20s do work. There are a lot more tires available for 22s. Get an ATV tire they don't get punctures like 2 ply can. You can go larger like 25s, more cost and more gearing and need a larger lift. The LT (long travel) lifts are nicer offroad and ride nicer, some fit larger than 22 tires. Ones that come with new shocks usually are significantly better as the stock shocks/springs are limited in what additional travel they can handle well. The spindle lifts look cool but don't usually make the cart ride/handle much better, there is a reason atv have double arm fronts. The larger tires will help it ride nicer over stock even with a budget lift, just because they are larger.

03-10-2013, 05:08 PM	#4
STSClays.com Getting Wild Join Date: Mar 2013 Posts: 77	Re: GX390 + 2003 Club Car DS Electric = ? My plans include a Comet CVT and Forward/Reverse Trans.
STSClays.com Getting Wild Join Date: Mar 2013 Posts: 77

03-10-2013, 06:49 PM	#5
sho305 Vegas modded 420 Join Date: Jun 2009 Location: West MI Posts: 15,443	Re: GX390 + 2003 Club Car DS Electric = ? We are here to help lol. I say the ezgo rear because with the clone I wish I had posi at times but I have no idea what the cost on them is compared to others. The ezgo cradle is very simple and similar to what I would make for any cart if I were fabricating one. Though I would use coilovers and not leaf springs. Once you get a rear you can get a secondary to fit, then a primary for the clone. Some (or all?) CC used a 1" belt so watch out for that, most ezgo and yamaha use 1 3/16 which is somewhat standard and much more available in various sizes. If you fab a cradle you should check out some of the builds of 3 link and other rears that really help the cart, though some are pretty serious offroad carts.

Today
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03-14-2013, 09:48 PM	#7
STSClays.com Getting Wild Join Date: Mar 2013 Posts: 77	Re: GX390 + 2003 Club Car DS Electric = ? Well, I cut out the Battery Supports today and will get to work installing a Lift Kit tomorrow if it arrives. I will then begin work on an engine cradle. I just wished there was a good source for used parts for these things. My friend has a DS cart that has an engine cradle that mounts to the rear Leaf Spring Pads. He has no idea where it came from as that is the way he got the cart but I will just build mine similar to his. Joe
STSClays.com Getting Wild Join Date: Mar 2013 Posts: 77

03-15-2013, 08:38 PM	#8
tjb406 Gone Wild Join Date: Jan 2013 Location: chester ohio Posts: 150	Re: GX390 + 2003 Club Car DS Electric = ? check out my build thread there are a couple pics of the cradle i built in it ,it bolts to the six bolt holes on the rear axle. and goes forward to the angle at the rear of where the brake braket welds on. bought a club car basket case under members rides.

03-15-2013, 08:43 PM	#9
sho305 Vegas modded 420 Join Date: Jun 2009 Location: West MI Posts: 15,443	Re: GX390 + 2003 Club Car DS Electric = ? If you look in the build and offroad threads there are plenty of photos of that stuff. Also look at the ezgo cradles for sale (new ones aftermarket). Only thing you really need to consider is how you support the axle, they usually need to mount where the stock cradle did so you don't break an axle tube or something like that due to poor support. And that depends on what rear you get.

03-17-2013, 08:50 PM	#10
STSClays.com Getting Wild Join Date: Mar 2013 Posts: 77	Re: GX390 + 2003 Club Car DS Electric = ? Well, I decided that instead of buying a transmission for reverse I would just buy this instead. surplus center in lincoln, ne has a reversing rearend for $ 329.00 + shipping.... www.surpluscenter.com part # 13-1468 It looks like a nice unit and will be super simple to build an engine cradle off of. The spring perches are welded onto the axle on top so that will make for an easy conversion if the spacing is correct.
STSClays.com Getting Wild Join Date: Mar 2013 Posts: 77

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