lifted club cars - lifted ezgo
Home FAQDonate Who's Online
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Club Car
Electric Club Car Electric DS, and Precedent golf cars



Post New Thread  Reply
 
Thread Tools Display Modes
Old 05-12-2015, 07:20 PM   #1
klanel
Gone Wild
Club Car
 
Join Date: Apr 2015
Location: Athens, GA
Posts: 349
Default 1992 Club Car DS - Renovation Project

Today I started what will probably be a long renovation project. Bought the cart for $150 with charger, sold the charger for $170 and at this point have a golf cart plus $20. But then that's the nearly $1K I've spent on a Accutrax 500 amp controller, high amp solenoid, etc. Will convert from 36 to 48 volts. Cart has cargo box on rear which I may change to a folding rear seat unless I can find a seat that will slide into the cargo box. Want to add lift kit, replace headlights, add tail lights, and larger wheels and tires. Will also paint the body. Here is where it's at currently.
Attached Images
File Type: jpg top_removed.jpg (46.8 KB, 0 views)
File Type: jpg front_end.jpg (117.6 KB, 0 views)
File Type: jpg steering_bushing.jpg (83.5 KB, 0 views)
File Type: jpg battery_box.jpg (120.4 KB, 0 views)
File Type: jpg battery_acid.jpg (97.6 KB, 0 views)
klanel is offline   Reply With Quote
Alt Today
BGW

Golf car forum Sponsored Links

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum
   
Old 05-12-2015, 07:24 PM   #2
klanel
Gone Wild
Club Car
 
Join Date: Apr 2015
Location: Athens, GA
Posts: 349
Default Re: 1992 Club Car DS - Renovation Project

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.
Attached Images
File Type: jpg motor.jpg (87.0 KB, 0 views)
klanel is offline   Reply With Quote
Old 05-13-2015, 08:56 AM   #3
Engman69
Not Yet Wild
 
Engman69's Avatar
Club Car
 
Join Date: Aug 2014
Posts: 17
Default

It looks like you have some work ahead of you. There are plenty of sites out there that can provide data on the parts and specs for your cart.
I'm in the final stages of a frame - up restoration of a 93 DR gas. It's not exactly the same as restoring an electric but not all that different either. If you have any questions about the non-electric stuff I'll be happy to share my experiences over the last 9 months.

The parts manual for the DS can be found online fairly easy.

[ATTACH]11[/IMG]9631[/ATTACH] August 2014

uploadfromtaptalk1431525258218.jpg May 2015
Attached Images
File Type: jpg uploadfromtaptalk1431525128914.jpg (209.7 KB, 0 views)
Engman69 is offline   Reply With Quote
Old 05-13-2015, 07:58 PM   #4
klanel
Gone Wild
Club Car
 
Join Date: Apr 2015
Location: Athens, GA
Posts: 349
Default Re: 1992 Club Car DS - Renovation Project

Quote:
Originally Posted by Engman69 View Post
If you have any questions about the non-electric stuff I'll be happy to share my experiences over the last 9 months.
Thanks for the offer, I hope it doesn't take me 9 months but that will depend on how quick I decide to spend the money.

Got the cargo box and covers off this evening. The front bumper plate is bent and since it's welded on, I don't know how I will straighten it If it was steel, I'd cut it off and weld on a new one but my aluminum skills aren't there.

I'm wondering if the battery box is supposed to have wood in the center? Any suggestions on the wiring? I'm leaning toward replacing all of it.

Also, what's the best way to clean the corrosion off the aluminum angle? The only thing I know to do is scrape it off.
Attached Images
File Type: jpg cart_rearview.jpg (115.2 KB, 0 views)
File Type: jpg battery_box.jpg (140.3 KB, 0 views)
File Type: jpg wiring.jpg (164.4 KB, 0 views)
klanel is offline   Reply With Quote
Old 05-14-2015, 09:38 AM   #5
PuttPutt
Gone Wild
 
PuttPutt's Avatar
E-Z-GO
 
Join Date: Jan 2012
Location: Chico, California
Posts: 496
Default Re: 1992 Club Car DS - Renovation Project

Some day I will jump in and do one. I was looking at a 85 CC and adding up the parts. LOL gets expensive fast. This is the route I want to take. Scotty's conversion kit. http://www.cartsunlimited.net/Scotty...rsion_Kit.html
I'll be following along. Have fun
I don't think the wood is normal. As for cleaning, good old baking soda and elbow grease. While chipping the hard stuff use a dust mask and eye protection.
PuttPutt is offline   Reply With Quote
Old 05-14-2015, 09:45 AM   #6
PuttPutt
Gone Wild
 
PuttPutt's Avatar
E-Z-GO
 
Join Date: Jan 2012
Location: Chico, California
Posts: 496
Default Re: 1992 Club Car DS - Renovation Project

You probably know but remember when you clean the frame with water and baking soda it is going to stain you cement floor. I cleaned a real bad one over a large piece of plastic then rolled up the mess and tossed it.
PuttPutt is offline   Reply With Quote
Old 05-14-2015, 09:49 AM   #7
klanel
Gone Wild
Club Car
 
Join Date: Apr 2015
Location: Athens, GA
Posts: 349
Default Re: 1992 Club Car DS - Renovation Project

Quote:
Originally Posted by PuttPutt View Post
You probably know but remember when you clean the frame with water and baking soda it is going to stain you cement floor. I cleaned a real bad one over a large piece of plastic then rolled up the mess and tossed it.
Thanks, didn't know that but was concerned about the acid on the concrete. Will pull outside and clean it there.
klanel is offline   Reply With Quote
Old 05-14-2015, 03:12 PM   #8
DJGCWB
Getting Wild
 
DJGCWB's Avatar
Club Car
 
Join Date: Mar 2015
Location: Houston, TX
Posts: 131
Default

Wood under the batteries is definitely not how it comes from the factory. There should be aluminum angles there as well. They probably corroded and the previous owner just used wood to support the batteries. Many ways to skin a cat!

Those aluminum angle battery trays look pretty bad. I would suggest just cutting them out and replacing them with new aluminum angles. Very cheap and easy to do. Probably cheaper and easier than trying to clean and restore them and you will be much happier with the end product.
DJGCWB is offline   Reply With Quote
Old 05-14-2015, 03:16 PM   #9
DJGCWB
Getting Wild
 
DJGCWB's Avatar
Club Car
 
Join Date: Mar 2015
Location: Houston, TX
Posts: 131
Default

I'm finishing up a restoration project of a 83 CC DS. Check out the thread, there will be helpful info in there that will help you along the way. Oh and definitely replace all of the wire and cables.

http://www.buggiesgonewild.com/showthread.php?t=103944
DJGCWB is offline   Reply With Quote
Old 05-14-2015, 04:42 PM   #10
Engman69
Not Yet Wild
 
Engman69's Avatar
Club Car
 
Join Date: Aug 2014
Posts: 17
Default

It looks like a pretty good platform to build on. For the frame you could try a good pressure washing. Then wire bush the corrosion and re-alodine the bare aluminum.

For my DS all the wiring was replaced. The wiring diagrams are in the parts book. It wasn't difficult.

Wood in the bottom of the battery box is bad IMO. Wood holds moisture and moisture leads to corrosion. I'd get rid of it and fix the box as needed. When I replaced my batt box I cut out the channel and rivited in new channels using aircraft grade hardware.
Engman69 is offline   Reply With Quote
Reply
Go Back   Buggies Gone Wild Golf Cart Forum > Golf Cart Repair and Troubleshooting > Electric Club Car


Thread Tools
Display Modes


Similar Threads
Thread Forum
E-Z-GO Marathon renovation Electric EZGO
1992 ezgo marathon clone project Clone Engine Swaps
Advice with Marketeer renovation for hill use Electric golf carts
1992 EZGO Project Gas EZGO
New Project-1992 Gas Ez Go Gas EZGO


All times are GMT -5. The time now is 09:40 PM.


Club Car Electric | EZGO Electric | Lifted Golf Carts | Gas EZGO | Used Golf Carts and Parts

Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2024, vBulletin Solutions, Inc.
This Website and forum is the property of Buggiesgonewild.com. No material may be taken or duplicated in part or full without prior written consent of the owners of buggiesgonewild.com. © 2006-2017 Buggiesgonewild.com. All rights reserved.