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Unread 04-04-2009, 08:07 PM   #1
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Talking MY MONEY PIT... Start to Finish, Finally!!!

Here's what I started with in December:

1998 Series Club Car, 48V, 100% stock plus rear seating.

Now the fun begins...
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Unread 04-04-2009, 08:09 PM   #2
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Default Re: MY MONEY PIT... Start to Finish, Finally!!!

Disassembled almost...
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Unread 04-04-2009, 08:13 PM   #3
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Default Re: MY MONEY PIT... Start to Finish, Finally!!!

AllSports long travel lift front and rear installed with new dash cover.
Lots of wires to clean up...
ITP SS rims with all trails 23x10.5x12
trying to support radio in it's cutout.
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Unread 04-04-2009, 08:30 PM   #4
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Default Re: MY MONEY PIT... Start to Finish, Finally!!!

One part that slowed me down considerable was fabricating a resting place for the extra 12v battery to power the accessories. Didn't want to draw off the pack. Ended up removing the vertical aluminum panel that held the controller and solenoid and OBC... laying it flat (little bit of trimming) and Tek-screwing it to the frame. Battery is supported very well. Able to use the same mounting place for the OBC in the aluminum panel (note direction of neg cable passing through is VERY important). Installed Alltrax 500amp AXE controller, HD solenoid, terminal strip. Note, this is NOT a good place to install a terminal strip! I hope I never have to get to it. Very convienient with the body off! I used some 4ga ultraflex wires. It was a little more pricey but much more flexible. I thought it would help in running the wiring... don't need to do that either. Oh well, at least the orange color is different than black. It's got a very high strand count, too...
The clearance between the battery posts and the body is less that 1/2". Good thing I measured it twice!
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Unread 04-04-2009, 08:40 PM   #5
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Default Re: MY MONEY PIT... Start to Finish, Finally!!!

Another part that slowed my progress (well, not too much didn't slow my progress) was replacing the v-glide with a PB-6. I wanted smooth acceleration and needed something more heavy duty in case I up the ante to 72v down the road. My problem was using the original accelerator rod to directly attach to the PB-6 lever arm. It wouldn't translate the arm across its complete throw. A couple guys fabed up some cool brackets and springs but I thought up another way to skin the cat. The pic on the right got rotated 90 degrees but I basically extended the attachment point of the accelerator rod by 2". I don't recommend doing this unless you also fabricate some protection for this since it extends below the protection of the frame by 2". That'll come later.
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Unread 04-04-2009, 08:52 PM   #6
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Default Re: MY MONEY PIT... Start to Finish, Finally!!!

Here's my carbon fiber dash installation with the radio cutout. Only two cupholders, that's all I need to hold my Old English 40oz
Put in a turn signal kit also here.
Look at those pedal inserts. Much Old English was consumed trying to "insert" or rather beat with a ten lb hammer into place! Those things would not go on! I ended up taking the accelerator pedal off and beating the crud out of it to get it to go on. The brake pedal I could not remove from the cart so I came up with a system of three heavy duty clamps mounted horizontally across the large part (not the little park piece which slid right in) and tightened each one by one making myself a press. Worked great (well, it's got about 1cm more to go if you look closely)
Gotta have the bling
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Unread 04-04-2009, 09:53 PM   #7
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Default Re: MY MONEY PIT... Start to Finish, Finally!!!

It looks great!!! My 89 CC/DS is in the garage stripped down to the frame, after looking at your pics, I have along way to go.
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Unread 04-04-2009, 10:04 PM   #8
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Default Re: MY MONEY PIT... Start to Finish, Finally!!!

And here it is... Finished it off with more bling-
diamond plate floor, kick panel, and access cover
chrome nerf bars, SS rocker panels
Kenwood stereo, bluetooth
keyed switch
Rear seat armrests with cupholders (won't hold my Old English 40s but then again, I'm the driver!)
HD F/R switch
custom grey/black seats with black piping (I know, still need to finish the backs of them)
metallic paint (GM color code)
BTW, if you add a 6" rear lift AND HD leaf springs you WILL need new u-bolts- sponsors...
It still needs some little fine tuning but it's finally on the road (and a little off).
Some more goodies to install (6:1 gears, Beast, and soon disc brakes)
Gotta figure out a better horn switch than in the floor...any ideas??
Also need speakers...will make the stereo sound better probably.
Thanks to all who helped, couldn't have done it without BGW!!
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Unread 04-04-2009, 10:06 PM   #9
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Default Re: MY MONEY PIT... Start to Finish, Finally!!!

Quote:
Originally Posted by fldisneyfamily View Post
It looks great!!! My 89 CC/DS is in the garage stripped down to the frame, after looking at your pics, I have along way to go.
Cape Coral, nice. I bought this in North Ft. Myers. Always going to the Cape to fish with my brother-in-laws. Hope you have as much fun as I did. Don't hold back with any questions!
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Unread 04-04-2009, 10:55 PM   #10
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Smile Re: MY MONEY PIT... Start to Finish, Finally!!!

VERY NICE!!!
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