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Old 07-19-2014, 08:53 PM   #1
Danz91G2
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Default Stretching my Club Car without welding

BGW-

Although my username says I have a G2, that was our old cart. I just picked up a '92 Club Car and want to stretch it a bit. I'm not going for the limo idea where you can step through, but more of a Rhino Clone idea. Therefore, I want to stretch the frame probably less than 24 inches. Although I have a welder, I can't do aluminum. I was wondering if I could stretch the frame and then use Grade 8 bolts with reinforcing plates to strengthen it. I plan on using if for off-road with a lift kit, I know welding would be better, just want to do the stretch myself. Thoughts? I'm new to Club Cars.

CDR D

P.S. - I did a search, but the Club Car stretch from 2010's photos wouldn't show up.
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Old 07-19-2014, 11:10 PM   #2
Revolution
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Default Re: Stretching my Club Car without welding

Just my 2 cents here, depending on the use of the cart I would seriously consider finding an experienced aluminum welder. It you do all the prep work and have the material ready it shouldn't cost too much.

It will take a lot more material to make a bolt on strech kit than welding one in to keep the same strength.
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Old 07-20-2014, 07:02 AM   #3
hookm
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Default Re: Stretching my Club Car without welding

Danz,look up my post "Old People Doing Stuff".I did mine 2 yrs. ago & I beat the crap out of it at CAW,it has held up with no problems.
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Old 07-20-2014, 07:32 AM   #4
Danz91G2
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Default Re: Stretching my Club Car without welding

Hookm-

That's exactly what I needed to see, looks like it would work perfectly for me. The only reason I'm looking to stretch mine is because I have 3 boys and we all want to ride in it together. I could just get the rear seat setup, but we're looking for more of a "Rhino clone" look, so I want them facing forward. I want to stretch it out to give them more leg room behind me and the passenger. So I'd basically go the same route you did, but stretch the body forward. I would make 2 seat mounts and put racing seats on it like you did, then get either 2 more racing seats and mount them to the existing frame or something similar. Then I would have to get a cage built to tie it all together. I still have some designing to do, but what you showed is what I needed to see. Thank you SO MUCH!!

CDR D
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Old 07-20-2014, 07:56 AM   #5
Danz91G2
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Default Re: Stretching my Club Car without welding

Oh, for the record I do not think I'm going to build a cart that will outperform a Rhino per se. Just looking to get a different seating arrangement for the boys to ride in.
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Old 07-20-2014, 12:06 PM   #6
hookm
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Default Re: Stretching my Club Car without welding

Let me know if I can help
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Old 07-22-2014, 03:22 PM   #7
Shack
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Default Re: Stretching my Club Car without welding

I stretched my 1984 33" without welding aluminum. I stripped it down, cut out the aluminum floor and cut the frame in the middle. I built a steel subframe out of 2x3 (or 4") steel. The aluminum I-beam pushed inside the steel channel about 6" and through-bolted. Because the CC frame "V's" to a point in front, I finished welding the steel subframe after the two halves were assembled. The I-beams are almost a hammer fit into the channel, the angle of the beams and subframe locks the assembly together when welded up, then through bolt and bam, you've stretched it out.

I welded outriggers down the outside of the steel frame, and used 1X3 steel channel to replace the outside rails, and welded flat plate steel to the entire structure for the floor.
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Old 07-23-2014, 04:16 PM   #8
oddpowers
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Default Re: Stretching my Club Car without welding

I stretched mine with out welding as well. I have a thread on here, but all my pictures got screwed up when I organized my photobucket (wont do that again..)
Anyway, here are a couple pics of how I did it.















We drove this cart one year at one of the CAW outings. Did fine no problems (not with the stretch anyway) Also pushed snow with it one year.
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Old 07-23-2014, 04:41 PM   #9
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Default Re: Stretching my Club Car without welding

Very similar to my build, but in my habit of making things more complicated than they need to be, my internal steel frame mimicked the angles of the aluminum frame, ie, when you look from below it looks like the original aluminum frame is "extended" with the the steel box running at basically the same angles. Where you added the plate on the outside aluminum rails, I cut them off and made a whole new rail from steel in the same position. Welded the floor to the structure.

Mines been done 2 years and you can park a truck on it still. Solid as a rock.

I extended the gas and brake with rod. I also put in a floor shifter (from a car) and mounted the trans shift cable to the frame, then used a rod from the shifter to the shift cable. All has been flawless.
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Old 07-23-2014, 07:49 PM   #10
paintchip31
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Default Re: Stretching my Club Car without welding

Hey oddpowers what are those seats from?
Also Dan will you post some pics of yours?
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