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Unread 03-09-2016, 12:09 PM   #1
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Join Date: Jul 2014
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Default Fabricating Roof for '96 Club Car DS - Fiberglass Experience Wanted

So I fabricated an overhead console last summer and hung it from the factory supports - I wanted ALL the stereo/electronics overhead to keep them dry and secure, unfortunately the design was flawed for two reasons, mostly because I started the project without the cart here.....hindsight 20-20.

#1 - the hangers were bent using aluminum not welded steel causing them to sag literally when I hit the first few bumps.
#2 - the box itself should have been larger to connect to all 4 posts to prevent swaying around corners.

I'm looking to purchase/install a rear seat kit (open to recommendations!), and considering fabricating a fiberglass roof the same size as a 84" top -- building the stereo speakers/radio/electronics enclosure to be integrated to it -- a single piece design much lighter in weight and able to connect to the four factory supports.

I've never worked with fiberglass and caused my hesitation to just start that way last time.and then start over to be ready for this summer. Any ideas/advice considered here before I start.

My primary question is to handle the stress of speed bumps and general on road driving -- for the internal support frame around the outer ring of the roof to run the bolts thru:

* is fiberglass only strong enough to bolt thru without stress cracking? (to minimize the internal weight)
* should I consider a 1x1 screwed together at the ends, rounded corners etc (and also use it for the frame to stretch the fleece/fiberglass across?)
* should I consider an aluminum edge pop-riveted to the fiberglass? (I would have to find a scrap trim from an existing roof OR have one fabricated)

Any thoughts in advance would be appreciated - my wife is already sick of this project!
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Unread 03-09-2016, 01:53 PM   #2
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Default Re: Fabricating Roof for '96 Club Car DS - Fiberglass Experience Wanted

Just a question, how sturdy is the roof itself? will it support the console if you bolt the console right to the roof? Might be the best way to go if the roof will support it.
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Unread 03-09-2016, 04:49 PM   #3
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Default Re: Fabricating Roof for '96 Club Car DS - Fiberglass Experience Wanted

I had an overhead radio unit on my first cart, I had to rivet it through the roof from the outside, which they supplied the rivets. The 4 post sway too much when not on a smooth road, everything would twist with the bumps and rattle. Even though I never had a worry of it falling apart or down, the weak link was the supports by design twist with the terrain.
I worked with fiberglass before, I'm sure it could be done but not sure if you will want to do what it will take to the extend of it being a solid roof.
Just my thoughts, like what you have, maybe it would be simpler to modify that, I think would be a better option.
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Unread 03-11-2016, 10:22 AM   #4
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Default Re: Fabricating Roof for '96 Club Car DS - Fiberglass Experience Wanted

Thanks for the replies and thoughts, I think step one is to settle on the rear seat kit and see how that will alter the upper supports. I suspect that will improve the swaying with swapping out the basket / clamping for the rear posts with a sturdier bracket.

Worst case I may run aluminum between the four corner posts, overhead console on top of a square frame that will bolt up to the posts. The biggest problem is the roof is not flat, it has all the crazy molded curves - and if I do "raise the roof" it will help with the head clearance for taller passengers.

I don't mind the project side of the approach - I just want it to WORK this time since I know the wiring with the breakers/voltage reducer/fuse blocks is working by design!
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