Might as well do a 1990 CC DS conversion/upgrade thread !!

[Threewheelmotion]

Aight guys. This was a given to me cart so I decided to do a little research. Found it this was a vglide with resister coil set up. I didn’t know crap about any of that. No big deal. So I researched all of it on here and you guys are always amazing and helpful. So I decided, well these batteries are kind of weak, the wiring looks like crap, and most of the connections are rusted or corroded. So I decided to rip it all out and star from scratch. ((Please keep in mind that I am trying to do this without breaking the BANK ! So I didn’t just go out and buy everything from a sponsor or retailer.))

After much deliberation I ended up with a pb-6 for my throttle and also had to fab up my linkage.”don’t worry, I will post pics below”. In my mind, I am about half way though this process but I’m sure there will be more things that rear their ugly head as I go along. For a controller I went with a alltrax SPM 48v compatable 400 amp. Ordered the 400 amp HD solenoid and reversing contractors from Scottyb. Found an ERIC 48v charger for the low low price of 180 bucks but I will have to install a new receptacle in the cart body to accept the three pin plug. I also upgraded all wires to 2 gauge. I believe I have everything I need except batteries at this point.

OH, I almost forgot to mention. I pulled the motor which was welded to the armature “After fighting it for a few days, I ended up dropping the axle and hitting it on the concrete to get it loose”. I broke it down and replaced brushes and bearing. Also cleaned off the communicator a bit and inside the casing. Sorry I didn’t get pics of that process but there are plenty of threads on the subject. At any rate, I will post some pics in a little while. About to head to work !

P.S. This will not be a perfectly written thread. I have a full time job and a 5 month old. So it will probly be pieced together but I will try very hard to answer questions and keep up !! Also, there will probly be some jerry rigging and things that are not done to “spec”. Please don’t be a dick. Lol. THANKS FOR WATCHING !!

[Springbok]

Subscribed.

[Threewheelmotion]

Ok folks !! Sorry it took so long. It’s been a busy day. Let’s start from the beginning. I’m not going to be to mouthy and explain every little thing I did. Ok try to keep it short. This is what the cart looked liked when I got it. Seats were dry rotted. Under the seat all the wires were users and funky. I’ll transition into stripping it down.

[Threewheelmotion]

Ok dokie ! When I first started I replaced the key switch and battery water and I was then able to drive t around. Once I got to driving it I noticed the front bearings were squealing something aweful. So I replaced them and cleaned up the front suspension a little. “Knocked the dirt off and greased the fittings.” I also ordered some led light bulbs for the headlights. They didn’t fit perfectly so I had to do some retro fitting. Sorry I didn’t take pics. I was to mad about them not just popping in. Now. I have pics of the seat that I recoverd so I will add them now. I replaced the wood and painted all the aluminum with rustoleum hammered silver. Anything you see that is pint or that I say I painted. I did t with that brand and type. It’s the best in my opinion.

[Threewheelmotion]

Ok. On to the strip down !! I followed Scottyb’s instructions and just ripped out everything. Only wires in it right now are lights and ignition. Ignition wires will be replaced as well. Next up will be the clean up and some paint.

[Threewheelmotion]

Now that all the old crap is out of the way, I cleaned it all with a wire brush that you stick in a drill and then painted it. I couldn’t get it all but I’m not keeping this cart forever so I got it the best I could. I know what your thinking ! Why didn’t he just take the body off. It would have been much easier. Well, here is the reason. If I did that I would have wanted to clean every **** thing and replace all of the body bolts. I just let don’t have that kind of time. You probly noticed that I dropped the rear axle in the previous set of pics. That was so I could get this god forsaken armature off of the shaft. Listen to me !!! DO THE DROP METHOD !! Worked like a charm. If I wasn’t so hard headed and done that the first time, it would have saved me about 12 hours of babying that **** armature. It was **** near welded on from rust. I have already drained the diff fluid and replaced it. I also cleaned the armatureand inside the housing, replaced the brushes, bearing, and also had the privilege of breaking a ceramic washer. By the way, those are a rare commodity! I left the inside ceramic washers and replace two of the outside ones with the same size nylon washer. I did a continuity test once it was all put back together and nothing was grounded to the motor housing or a to s. So I decide, what the hell, it should hold up fine. I dropped a dab of red lock tight on them. I will probly never take them off again. I am assuming That’s the first time they have been touched since 1990.

[Threewheelmotion]

After a lot of deliberation, I decided to go with a pb-6 controller. I mounted up high to keep it out of the elements. My throttle linkage that went from the pedal to vglide was rusted to pieces so I replaced it all with 1/4 allthread and the stainless eyebolts. Almost everything I used was stainless in the entire build. Except for the rod and brackets I made. I drew a lot of inspiration for this set up from others on BGW. Inside of the eyebolts I used some small nylon washes that almost took up all of the extra “slop” inside the eye bolts.

[scottyb]

Where did you get that great idea

[Threewheelmotion]

Let’s move on to the fun stuff !! I wanted to have a nice clean place to mount the controller, solenoid, and 48-12 converter. I went and picked up some angle iron and cut to size. I didn’t want to use wood since it was going to be in a damp area. So I had an old 1/4 inch thick cutting board that I recycled. I also figured it was better than metal since it doesn’t conduct electricity and it’s reltivlt soft so wires can run on it. Her are a few pics.

THIS KS WHERE I NEED A LITTLE HELP. I screwed up and orders a cable kit for ezgo and some seem to be way to long for what I need. I am thinking about running each one through a hole in the cutting board. I think it would look good and keep them from rubbing on metal. I also got the reverse contractors from Scotty b. So I have another bracket I need to make across from the pb-6. I haven’t started that. So. That do y’all think I should do with the cables. Just run them over the board of through it ??

[Threewheelmotion]

Originally Posted by scottyb

Where did you get that great idea

Oh you know ...it just came to me !! Lol.