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Unread 07-03-2015, 01:03 PM   #41
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Default Re: 1992 Club Car DS - Renovation Project

I see no reason what you are saying would not be just fine.
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Unread 07-04-2015, 10:20 AM   #42
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Default Re: 1992 Club Car DS - Renovation Project

Thanks klanel, I appreciate it. I'll be installing the SPM48400 controller.
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Unread 09-24-2015, 03:31 PM   #43
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Default Re: 1992 Club Car DS - Renovation Project

Quote:
Originally Posted by klanel View Post
Another,..

I didn't realize the frame was aluminum. There is a lot of corrosion on some of the angle in the battery box. Also, is it normal to have boards in the center section for the batteries to sit on? I took a photo of the motor but don't see a HP rating.
we have the exact cart mines just a 90. you have a 2.0 hp motor 2800 Rpm series motor. Call Rick at Plum Quick motors and he can hook you up.
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Unread 09-24-2015, 06:34 PM   #44
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Default Re: 1992 Club Car DS - Renovation Project

Quote:
Originally Posted by TEly View Post
we have the exact cart mines just a 90. you have a 2.0 hp motor 2800 Rpm series motor. Call Rick at Plum Quick motors and he can hook you up.
Have a Bandit installed and in the process of putting it back together.
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Unread 06-04-2016, 06:03 PM   #45
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Default Re: 1992 Club Car DS - Renovation Project

The renovation is for the most part complete. Here are some more photos from the project.

My letters on the F/R lever were faded away so I sprayed paint over the face, sanded back off leaving the paint in the recesses. Covered that with polyurethane.

I also wanted a way to trigger the 1/2 speed reverse option on the Alltrax. Since I didn't have an extra set of contacts on the F/R switch I decided to use a magnetic contact with the magnet epoxied in the back side of the F/R switch handle and I placed a contact inside the battery box that closes when the handle is turned to the reverse position.
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File Type: jpg FR lever.jpg (52.9 KB, 0 views)
File Type: jpg FR lever finished.jpg (107.4 KB, 0 views)
File Type: jpg half speed reverse.jpg (83.7 KB, 0 views)
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Unread 06-04-2016, 06:07 PM   #46
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Default Re: 1992 Club Car DS - Renovation Project

Altrax, DC/DC converter, fuse blocks, and terminal strips.
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File Type: jpg electronics mounting.jpg (168.0 KB, 0 views)
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Unread 06-04-2016, 06:09 PM   #47
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Default Re: 1992 Club Car DS - Renovation Project

Front cowl and rear body painted. Later I sanded it down with 2000 grit sandpaper and buffed out to a shiny finish.
Attached Images
File Type: jpg body_1.jpg (87.6 KB, 0 views)
File Type: jpg body_2.jpg (103.5 KB, 0 views)
File Type: jpg front_end1.jpg (124.1 KB, 0 views)
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Unread 06-04-2016, 06:19 PM   #48
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Default Re: 1992 Club Car DS - Renovation Project

Old and new battery box, installed Caddy Lift (gas spring) to hold seat up.
Attached Images
File Type: jpg batt_box.jpg (119.0 KB, 0 views)
File Type: jpg new batt box.jpg (165.0 KB, 0 views)
File Type: jpg caddy lift.jpg (208.1 KB, 0 views)
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Unread 06-04-2016, 06:30 PM   #49
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Default Re: 1992 Club Car DS - Renovation Project

The day I picked it up, the frame with the body and cargo bed removed and what it turned out like after many thousands and a year later.
Attached Images
File Type: jpg cart_day1.jpg (142.0 KB, 0 views)
File Type: jpg car_day1a.jpg (166.2 KB, 0 views)
File Type: jpg finished 1.jpg (337.6 KB, 0 views)
File Type: jpg finished 2.jpg (143.2 KB, 0 views)
File Type: jpg finished 3.jpg (146.2 KB, 0 views)
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Unread 06-04-2016, 06:32 PM   #50
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Default Re: 1992 Club Car DS - Renovation Project

And more,...
Attached Images
File Type: jpg finished 4.jpg (235.8 KB, 0 views)
File Type: jpg finished 5.jpg (184.2 KB, 0 views)
File Type: jpg finished 6.jpg (180.9 KB, 0 views)
File Type: jpg finished 7.jpg (156.6 KB, 0 views)
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