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Electric Club Car Electric DS, and Precedent golf cars



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Unread 06-30-2015, 07:27 PM   #31
Gone Wild
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Default Re: 1992 Club Car DS - Renovation Project

The demo is over and rebuild has started. Whatever was run into causing the bumper to get bent caused 3 welds to break and a couple of stress cracks which have now all been repaired.

The welds were an easy repair but the stress cracks required a little more thought. I ended up making a couple of plates that would bridge over the crack tying into the metal above and back to the framing tube. Photos below show the before and after.
Attached Images
File Type: jpg stress crack left side.jpg (176.2 KB, 0 views)
File Type: jpg stress crack right side.jpg (52.2 KB, 0 views)
File Type: jpg aluminum scab.jpg (57.2 KB, 0 views)
File Type: jpg crack repair left side.jpg (66.3 KB, 0 views)
File Type: jpg crack repair right side.jpg (62.9 KB, 0 views)
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Unread 06-30-2015, 07:37 PM   #32
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Default Re: 1992 Club Car DS - Renovation Project

And when I got it the battery boxes were eaten up with battery acid, especially the left side. It actually cleaned up and would have been usable but I decided to weld in some new ones on both sides.
Attached Images
File Type: jpg battery_acid.jpg (97.6 KB, 0 views)
File Type: jpg battery_box_cleaned.jpg (117.3 KB, 0 views)
File Type: jpg new battery box.jpg (79.7 KB, 0 views)
File Type: jpg cart frame.jpg (130.8 KB, 0 views)
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Unread 06-30-2015, 07:57 PM   #33
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Default Re: 1992 Club Car DS - Renovation Project

And some more,.. Made a bracket for new solenoid and placed where old one was, mounted throttle linkage and potentiometer.
Attached Images
File Type: jpg solenoid mounting.jpg (59.2 KB, 0 views)
File Type: jpg potentiometer mounting.jpg (66.2 KB, 0 views)
File Type: jpg potentiometer top view.jpg (81.1 KB, 0 views)
File Type: jpg throttle linkage.jpg (86.9 KB, 0 views)
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Unread 06-30-2015, 08:07 PM   #34
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Default Re: 1992 Club Car DS - Renovation Project

And more,..

Decided to mount the Alltrax facing forward. Used two aluminum angles, bolted the top one, welded mounting ears on the bottom one and bolted it in the side of the I-beam. Mounted a 48-12 vdc, 16 amp dc-dc converter beside the controller.

In the process of planning a color wiring scheme and efficient routing for the wiring.
Attached Images
File Type: jpg altrax mounting.jpg (74.1 KB, 0 views)
File Type: jpg controller and converter mounting.jpg (78.2 KB, 0 views)
File Type: jpg mounting rear view.jpg (95.3 KB, 0 views)
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Unread 06-30-2015, 08:40 PM   #35
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Default Re: 1992 Club Car DS - Renovation Project

Wow, what a transformation! Loving this build thread. Nice work!
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Unread 07-02-2015, 09:13 AM   #36
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Default Re: 1992 Club Car DS - Renovation Project

Nice job! I have just decided to fix up my '94 DS and I know I will need lots of advice and assistance once I get started. This thread will be my first source of reference material - thanks so much for all the information and pictures.
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Unread 07-02-2015, 06:33 PM   #37
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Default Re: 1992 Club Car DS - Renovation Project

If I may ask a couple of questions even though I haven't even begun my project...

I am not an engineer or an electrician, so...

1) What did you use for the throttle linkage? I will be putting in a "Curtis Style" PB-6 throttle and will need to develop something, or purchase something, that will facilitate the conversion from my 36V resistor coil/v-glide system to a 48V solid state system. I'm looking for ideas or recommendations.

2) I'm looking at an empty container (cart shell). I have no idea how the new system needs to be wired. That is the part of the project that keeps me up at night. Since my finished product will end up looking very similar to yours, could I ask you to post pics and a schematic? Also, aside from the 4AWG cables, what gauge wiring will you be using for the rest?

Thank you so much! This place will end up being invaluable to me.
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Unread 07-02-2015, 10:04 PM   #38
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Default Re: 1992 Club Car DS - Renovation Project

Breese and Chute, thanks for the positive comments. It was never my intention to do all this work but it got expensive quite fast and there was no turning back.

I've used other's postings here for inspiration as well and use them to influence how I go about doing my project. So far with the exception of expense, I'm satisfied with how it's going.

Chute, I'll be happy to help you anyway I can. I'm going to be using 2 AWG welding cables and whether or not I will notice any difference over #4, I can't say. If some here have personal experience, they can chime in. For the two wires going to the charger jack, I'll use #10 that will be good for 30 amps. The charger I'll be using will be slightly less so that will be sufficient.

For everything else, I'll be using 12 gauge which is good for 20 amps but I think it's overkill.

I will be using two 4 position ATC fuse blocks. One for 48vdc and the other for 12vdc and current plans are as follows but may change:

48vdc block
Cir 1 --> keyswitch (5A)
Cir 2 --> DC/DC converter (amperage unknown at present)
Cir 3 --> To charger jack (30A)
Cir 4 --> Spare

12vdc block
Cir 1 --> lightswitch (amperage unknown)
Cir 2 --> accessory power (15A)
Cir 3 --> radio (5A)
Cir 4--> Spare

I'll be adding a isolated ground terminal for the 12v side for the returns to the converter keeping it isolated from the 48v ground.

You will need a throttle bellcrank and if it's like mine, will need to have an offset to clear the batteries.

I haven't finalized my wiring scheme. Have a couple variations for the controller setup and have to incorporate the additional wiring/fusing for lights, accessories, etc. I can post my wiring diagram when I get it completed. If you have or are going to buy a controller, the manufacturer of the control will have one. I've got a Alltrax SPM48500 controller and if you go to their website, you can download schematics for different carts. But some devices/components you may or may not have on yours.
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Unread 07-03-2015, 07:11 AM   #39
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Default Re: 1992 Club Car DS - Renovation Project

No frame grounds on electric cart. The main pack neg can be used for all neg connections. I ran a wire from the neg block near the controller to my 12 volt fuse block.
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Unread 07-03-2015, 11:41 AM   #40
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Default Re: 1992 Club Car DS - Renovation Project

Quote:
Originally Posted by mrgolf View Post
No frame grounds on electric cart. The main pack neg can be used for all neg connections. I ran a wire from the neg block near the controller to my 12 volt fuse block.
Mr Golf, The DC/DC converter I am using has isolated grounds between the 48v input and 12v output. Since it doesn't really serve any purpose to connect the input/output grounds, I won't.

As for the ground block I will be using, it will just be for the 12 volt returns to tidy up the installation and will have no connection to the frame or the 48v return. As you mention the frame is not grounded, I can see why. If a battery cable frayed and touched the frame, lots of sparks could fly.

Still thinking through the wiring but this is what's in the plans for now.
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