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Unread 04-25-2015, 09:17 PM   #1
Gone Wild
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Default 1992 Club Car DS - Things to consider before undertaking modifications

I just purchased this cart from a friend for $150 with rear mounted cargo box and charger. The serial number is A9232294269 just in case that contains any relevant data.

It is currently a 36 volt system and all the batteries will have to be replaced. A couple of the tires are not holding air more than a few days, the headlights are missing from the holders, and may also need a new key switch if my buddy isn't able to locate the keys. Also, needs a new front bumper.

I did hook up the charger to the cart and it did not come on. It's a Lester Electrical so I didn't know if the charger was bad or because of issues with the batteries. It worked when he last used it but that's been several years ago.

Originally I had planned on just replacing the 6 volt batteries and keeping the cart in more or less original condition. But with the cost of batteries, etc, I'm thinking that it may be better to upgrade to a 48 volt system. The cart will be used at home for recreation, and as a utility vehicle and also taken to the lake to shuttle between the house and dock. Both places are somewhat hilly in places. There may be 3 adults and a child on the cart at one time. Approx 500 pounds max.

So my main question is what would the most economical way to convert from a 36 volt to a 48 volt system and still get a satisfactory level of torque for hauling people up hills. Please be specific with mfg/models since I'm new at all of this.
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Unread 04-25-2015, 09:54 PM   #2
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Default Re: 1992 Club Car DS - Things to consider before undertaking modifications

Be prepared to spend 2-3 thousand dollars. How is the fit and finish. It's got to look good if your hauling your family around.
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Unread 04-25-2015, 10:06 PM   #3
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Default Re: 1992 Club Car DS - Things to consider before undertaking modifications

Measure battery voltage. If it's too low, the charger won't kick in anyway. You can try to charge them individually with an automotive charger but they are probably junk anyway.
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Unread 04-26-2015, 01:42 AM   #4
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Default Re: 1992 Club Car DS - Things to consider before undertaking modifications

Welcome to BGW. As to your questions---

Tires--cart dealers usually have new or used take-offs from lifts and larger wheel customer jobs at reasonable prices.

Keys--If the key switch is stock, replacement keys can be had at the local dealer also. You can order them from several of the site sponsors but the shipping cost is a spoiler. I paid $3/key at my local dealer for my spares.

Charger + batteries--the charger has to "see" 24-30 volts before in will do it's thing. So the name of the game is to get each battery to about 5 volts using an automotive charger. If you don't have a 6 volt charger, you can charge 2 batteries in series with a 12 volt charger. Review the "Sticky" about batteries at the top of this section and make sure the fluid is covering the cell plates before charging. ONLY use distilled water if needed. After sitting for several years their only value may be as cores but it's worth a shot.

36 to 48--Except for the motor, all major power components will have to be upgraded. At 48 volts all the old stuff will fail (sooner or later). For the most economical way, go to the sponsor's page to pull up Carts Unlimited's phone number and talk to scottyB about what you want to do with this cart. His packages beat doing it a la carte. Scotty has walked lots of guys through what you want to do. While you're on the sponsor page, put Revolution Golf Cars' phone number on your speed dial too. TahoeDawgZ71 knows CC carts up, down and sideways. Between the two of them, you're covered.

Keep us posted on how this works out.
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Unread 04-26-2015, 03:44 PM   #5
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Default Re: 1992 Club Car DS - Things to consider before undertaking modifications

Thanks for the replys. I'd like to think I would never spend 2-3k but I know it will be at least 2k if I do everything I'm thinking of doing. As for the batteries, I don't have a voltmeter at home but it's been sitting for several years and the batteries were shot when he parked it.

The body is in pretty decent shape, Has a couple of small dings and a few surface scrapes and the clear coat is coming off in places but I'm going to repaint the thing anyway.

I'll get with the contacts you've provided on the conversions. It would be helpful to buy a package where everything is provided since I don't know the difference between one controller and another, etc. And the support would be valuable.

Current plans are to do the 48 volt conversion and get it up and running then tackling cosmetic issues later. After some of the sticker shock goes away, I want to lift it and add some larger tires/wheels. I will say though my wife would be very happy with 36 volt, small tires, no upgrades, painting,etc. She's very practical and myself like most men, want more power.

Thanks for the advice and information.
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Unread 04-26-2015, 06:18 PM   #6
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Default Re: 1992 Club Car DS - Things to consider before undertaking modifications

Quote:
I will say though my wife would be very happy with 36 volt, small tires, no upgrades, painting,etc. She's very practical
I can just heard her now. Every time the UPS truck pulls up to the house. "What did you order now." Another good reason to order the package from Scotty or Dave, get it all over at once.

That's how my wife is anyway.
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Unread 04-26-2015, 07:31 PM   #7
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Default Re: 1992 Club Car DS - Things to consider before undertaking modifications

How in the world do they all know to say the same thing.
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Unread 04-26-2015, 07:41 PM   #8
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Default Re: 1992 Club Car DS - Things to consider before undertaking modifications

Special wife training...lol
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Unread 04-26-2015, 09:33 PM   #9
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Default Re: 1992 Club Car DS - Things to consider before undertaking modifications

It's like bringing home a stray dog, after you give them time to fall in love with it, you're golden.

For as little as you paid for the cart and if you do all the work yourself, the added value will equal or exceed the money you put into it.



.
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Unread 04-27-2015, 04:47 PM   #10
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Default

Well if wife complains about all the ups packages make an Amazon wish list and get her a little something as well. But you will spend some money get the pocket book ready
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