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Unread 03-19-2016, 02:48 AM   #11
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Default Re: 2003 Club Car DS Refurbish/Upgrade/ Official thread!

The brakes have been touchy and locked up frequently ever since I purchased the cart. I took the passenger side off, sprayed some brake cleaner on the assembly and sanded down the pads. I had to loosen them quite a bit to get the hub back on. When I take off the driver side wheel to clean that brake, I'll tighten up the passenger side a little.
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Unread 03-19-2016, 02:49 AM   #12
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Unread 03-19-2016, 02:53 AM   #13
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Default Re: 2003 Club Car DS Refurbish/Upgrade/ Official thread!

Last summer, my 13yo backed the cart into a neighbor's Tahoe Z71. There was no outward damage to the cart. He bent the nerf bar and door of the Tahoe. When I crawled under the cart to work on the brakes, I noticed the leaf spring on one side was bent. Not sure if that is from hitting the Tahoe or it was bent before. It's hard to see in the pic. I'll take another one before I swap them out. I eventually want to get the rear seat. Headlights, Voltage reducer, and new leaf springs are my first priority!
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Unread 03-19-2016, 02:54 AM   #14
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Unread 03-30-2016, 06:40 PM   #15
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Woo Hoo! Big day so far! Started off drawing the template, and taping it off for the headlights and taillights!


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Unread 03-30-2016, 06:41 PM   #16
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Unread 03-30-2016, 06:46 PM   #17
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I drilled pilot holes. I did not use a Dremel. I decided to use a variable speed cordless jigsaw with a fine tooth blade. I have much more control and experience using it. For the rear headlights. I got caught up by the bumper on the left side and the blade jumped. I took the bumper off so I could have more control.
You can see in the lower right corner where the blade jumped before I took off the corner. Normally would not have been an issue but the fine tooth blade is short so I did not have the clearance.


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Unread 03-30-2016, 06:47 PM   #18
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Back and front now cut out. Nice tight fit!


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Unread 03-30-2016, 07:47 PM   #19
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Unread 03-30-2016, 07:48 PM   #20
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