Pimp my new to me DS

jelmhorst · 01-28-2016, 08:00 PM

Brand new to the cart family! I've been reading up on past threads getting ideas and learning about what I'm getting myself into and what all I want to add. I wanted a cart to shuttle myself and guests to my dock half a mile away. Found this ol girl and she was too good of a deal to pass up. $850 for 96 DS, 48v Series with 2 year old Interstate batteries and upgraded [maybe 4ga?] cables. Didn't want to spend the money on somone else's build so finding something that runs well but needed love was ideal. Cosmetically she needs a lot of love. She will spend her life outdoors until a garage can be built in a few years so I won't be going crazy on upgrades like a prime paint job until she can be safely stored.

The rear flip seat cushion underboard has rotted out and will need to be replaced. Anyone tried HDPE or just stick with marine grade plywood?

Due to the deep scratches and uneven-ness of the paint, stripping everything to the core is probably the best bet. Wetsand with 240grit/similar or has someone used a different grit with success? I thought I saw this on a previous thread. Most likely it will be plastidip until an investment can be made into a real paint job.

So the upgrades this year seem to be:
1. Grizzly basket and brush guard big enough to hold a good size cooler
2. Controller/solenoid upgrade. Does upgrading these help significantly with a stock motor or does it need to be a full system including the F/R, cables, etc? I'm not so much needing the top end speed yet, just confidence I can climb a 35% grade with 4 adults at more than a walking pace. I'm only on 18.5 x 8 tires so I'm not going big just yet.
3. Cosmetic stuff like new seat covers, etc.
Any other must have accessories?

Looking forward to continuing to learn from other's projects and I appreciate in advance all the help I will inevitably ask for as I undertake another toy to spend the money I should be saving for retirement. And as I've learned, pics or it never happened!

Thanks, Jeff

01-28-2016, 08:47 PM

Quote:

Originally Posted by jelmhorst

Brand new to the cart family! I've been reading up on past threads getting ideas and learning about what I'm getting myself into and what all I want to add. I wanted a cart to shuttle myself and guests to my dock half a mile away. Found this ol girl and she was too good of a deal to pass up. $850 for 96 DS, 48v Series with 2 year old Interstate batteries and upgraded [maybe 4ga?] cables. Didn't want to spend the money on somone else's build so finding something that runs well but needed love was ideal. Cosmetically she needs a lot of love. She will spend her life outdoors until a garage can be built in a few years so I won't be going crazy on upgrades like a prime paint job until she can be safely stored.

The rear flip seat cushion underboard has rotted out and will need to be replaced. Anyone tried HDPE or just stick with marine grade plywood?
pressure treated plywood is ok to use

Due to the deep scratches and uneven-ness of the paint, stripping everything to the core is probably the best bet. Wetsand with 240grit/similar or has someone used a different grit with success? I thought I saw this on a previous thread. Most likely it will be plastidip until an investment can be made into a real paint job.
plasti dip would be good til proper paint

So the upgrades this year seem to be:
1. Grizzly basket and brush guard big enough to hold a good size cooler

2. Controller/solenoid upgrade. Does upgrading these help significantly with a stock motor or does it need to be a full system including the F/R, cables, etc? I'm not so much needing the top end speed yet, just confidence I can climb a 35% grade with 4 adults at more than a walking pace. I'm only on 18.5 x 8 tires so I'm not going big just yet.
a bigger controller would be where i would go
http://www.cartsunlimited.net/series-controllers.html

3. Cosmetic stuff like new seat covers, etc.

Any other must have accessories?
heavy duty rear springs
good lighting
Looking forward to continuing to learn from other's projects and I appreciate in advance all the help I will inevitably ask for as I undertake another toy to spend the money I should be saving for retirement. And as I've learned, pics or it never happened!

Thanks, Jeff

yes we need photos

jelmhorst · 01-29-2016, 08:07 AM

Let's try that again...

Frizbgolf · 01-29-2016, 10:05 AM

The cart looks like it is in pretty good shape, will make a nice platform for you to build up the way you want.

joesam · 01-29-2016, 10:13 AM

Quote:

Wetsand with 240grit/similar or has someone used a different grit with success

Many years ago when I prepped my cart, I started with wet 240, but on the high spots & edges, I did get a bit of a mouse-fur finish, because the body material is soft/pliable. I think I finished the high/furry spots with 320 or 400. After prep I had it professionally painted and then clear coated. Came out beautiful.

01-29-2016, 12:14 PM

oh hell ... it's got white stuff on it

Epb · 01-29-2016, 09:48 PM

Thats a great deal in my opinion.
i would think you need to upgrade motor to torque to haul 4 peeps up a 35% grade. The 2.5 or 3.1hp original motor....you need to verify...may not cut it!

01-28-2016, 08:00 PM	#1
jelmhorst Not Yet Wild Join Date: Jan 2016 Location: Allatoona Lake, GA Posts: 20	Pimp my new to me DS Brand new to the cart family! I've been reading up on past threads getting ideas and learning about what I'm getting myself into and what all I want to add. I wanted a cart to shuttle myself and guests to my dock half a mile away. Found this ol girl and she was too good of a deal to pass up. $850 for 96 DS, 48v Series with 2 year old Interstate batteries and upgraded [maybe 4ga?] cables. Didn't want to spend the money on somone else's build so finding something that runs well but needed love was ideal. Cosmetically she needs a lot of love. She will spend her life outdoors until a garage can be built in a few years so I won't be going crazy on upgrades like a prime paint job until she can be safely stored. The rear flip seat cushion underboard has rotted out and will need to be replaced. Anyone tried HDPE or just stick with marine grade plywood? Due to the deep scratches and uneven-ness of the paint, stripping everything to the core is probably the best bet. Wetsand with 240grit/similar or has someone used a different grit with success? I thought I saw this on a previous thread. Most likely it will be plastidip until an investment can be made into a real paint job. So the upgrades this year seem to be: 1. Grizzly basket and brush guard big enough to hold a good size cooler 2. Controller/solenoid upgrade. Does upgrading these help significantly with a stock motor or does it need to be a full system including the F/R, cables, etc? I'm not so much needing the top end speed yet, just confidence I can climb a 35% grade with 4 adults at more than a walking pace. I'm only on 18.5 x 8 tires so I'm not going big just yet. 3. Cosmetic stuff like new seat covers, etc. Any other must have accessories? Looking forward to continuing to learn from other's projects and I appreciate in advance all the help I will inevitably ask for as I undertake another toy to spend the money I should be saving for retirement. And as I've learned, pics or it never happened! Thanks, Jeff

01-29-2016, 10:05 AM	#4
Frizbgolf Gone Wild Join Date: Nov 2009 Location: Picayune, Mississippi Posts: 881	Re: Pimp my new to me DS The cart looks like it is in pretty good shape, will make a nice platform for you to build up the way you want.

01-29-2016, 12:14 PM	#6
crash test dummy Guest Posts: n/a	Re: Pimp my new to me DS oh hell ... it's got white stuff on it
crash test dummy Guest Posts: n/a

01-29-2016, 09:48 PM	#7
Epb Gone Wild Join Date: Mar 2012 Location: Katy, Tx Posts: 1,027	Re: Pimp my new to me DS Thats a great deal in my opinion. i would think you need to upgrade motor to torque to haul 4 peeps up a 35% grade. The 2.5 or 3.1hp original motor....you need to verify...may not cut it!

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