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Unread 05-12-2015, 07:20 PM   #1
Gone Wild
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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.
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Unread 05-12-2015, 07:24 PM   #2
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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.
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Unread 05-13-2015, 08:56 AM   #3
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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
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Unread 05-13-2015, 07:58 PM   #4
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Default Re: 1992 Club Car DS - Renovation Project

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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.
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Unread 05-14-2015, 09:38 AM   #5
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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.
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Unread 05-14-2015, 09:45 AM   #6
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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.
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Unread 05-14-2015, 09:49 AM   #7
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Default Re: 1992 Club Car DS - Renovation Project

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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.
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Unread 05-14-2015, 03:12 PM   #8
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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.
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Unread 05-14-2015, 03:16 PM   #9
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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.

83 Club Car project
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Unread 05-14-2015, 04:42 PM   #10
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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.
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