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Unread 02-16-2015, 10:33 PM   #51
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Default Re: '97 48v Club Car

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Originally Posted by 93yellowclubcar View Post
I'll leave a bit of info for others facing Club Car battery tray rot. Many will tell you that you need to have a TIG setup and know how to weld aluminum to fix battery trays in a Club Car - that couldn't be further from the truth!!! With a stick of 1/8" thick by 1 1/4" aluminum angle, a drill, a hacksaw, a tape measure, and some rivets and a rivet gun, and a grinder you can keep your batteries in the cart and not falling under.

Simply grind the old trays out, measure the new angle and cut it, drill a hole for the hold down rod in the side while it is still out of the cart, and drill then rivet that bad boy in! Repeat for all rotted or broken battery trays. Rivets are the best method because they are low profile and won't rub through the case of a battery. Welding is OK, but less preferable because you have to be sure a weld doesn't stick up to cause a wear spot in a battery - rivets are easier and don't give you that worry!
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Unread 02-17-2015, 02:30 AM   #52
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Default Re: '97 48v Club Car

Sorry - been on golf vacation in Phoenix - haven't had much chance to catch up on the site - THIS LINK will show a riveted battery tray in a DS Body - not exactly like your original setup - but you'll get the idea of riveting angle pieces to hold batteries.
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Unread 02-17-2015, 08:58 AM   #53
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Default Re: '97 48v Club Car

Did you play in the Phoenix open.
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Unread 02-17-2015, 09:03 AM   #54
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Default Re: '97 48v Club Car

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Originally Posted by joesam View Post
Sorry - been on golf vacation in Phoenix - haven't had much chance to catch up on the site - THIS LINK will show a riveted battery tray in a DS Body - not exactly like your original setup - but you'll get the idea of riveting angle pieces to hold batteries.
Since Joesam's example is for the newer DSs with the different tray, here is a little better example
The Craigslist Club Car
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Unread 02-17-2015, 10:03 AM   #55
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Default Re: '97 48v Club Car

Well guys, thanks to yall, I now know what I need to do. Next thing is yo do it! I'll upload pics as soon as I get er done. Thanks guys.
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Unread 02-18-2015, 08:01 AM   #56
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Default Re: '97 48v Club Car

To Mrgolf - Phoenix Open....I wish. A friend is billeting 4 girls from the Symetra Tour in his large home in Mesa - and we're going out to support/watch them on Friday. Wish my swing felt as effortless as theirs looks! 3+ mos of no activity did nothing for my short game!

Good Photos CCF - that's the article I was thinking of, but couldn't find!
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Unread 02-18-2015, 08:09 AM   #57
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Default Re: '97 48v Club Car

Joesam,
A few years ago their tour had a stop at my home course. I sure wish I could swing the golf club like a girl.
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Unread 02-18-2015, 08:09 AM   #58
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Default Re: '97 48v Club Car

Well I got everything I need. Now just waiting for Saturday morning to rebuild the trays.

Got a little unlucky with the batteries and have a mixed pack. US and Trojans.
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Unread 02-18-2015, 08:16 AM   #59
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Default Re: '97 48v Club Car

Check the AH rating (specs) on each battery. Hopefully they are the same - if not, Sergio has developed a little electronic "thingy" that mounts between the pos/neg post of each battery. It will help you keep them from becoming unbalanced. I'll see if I can find the article. With a mixed pack, you'll need to add that to your job jar. Its not expensive to do, but a mixed set is almost guaranteed to drift out of balance over a few months (some batteries overcharge, some undercharge).

Mrgolf - I was going to say swing-like-a-girl but was hesitant. Smoooooth.
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Unread 02-18-2015, 08:52 AM   #60
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Default Re: '97 48v Club Car

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Originally Posted by joesam View Post
Check the AH rating (specs) on each battery. Hopefully they are the same - if not, Sergio has developed a little electronic "thingy" that mounts between the pos/neg post of each battery. It will help you keep them from becoming unbalanced. I'll see if I can find the article
Passive Voltage Bypass for 8v Battery
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