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Unread 02-14-2020, 09:24 AM   #11
Gone Wild
Join Date: Oct 2019
Posts: 242
Default Re: Club Car extended top (DoubleTake OEM) squeaks - remove rivets?

Originally Posted by ClubCar86 View Post
Oh yea, I see what you are saying. That is tough to eliminate!
So I drilled out all 14 rivets, disassembled the aluminum frame plastic corner brackets (came apart easily and didn't break) and blew out the rivet pieces with compressed air.

Then I cleaned off the aluminum top surface with denatured alcohol and put some 1" x 1/8" neoprene foam strip (adhesive on the aluminum side) across the 4 perimeter spans. Used #14 x 3/4 pan head SS screws with a flat washer and a 5/8" diameter neoprene washer (1/16" I think, possibly thinner) against the plastic top. I will probably order 1/8" thick rubber / neoprene washers, and try to find ones closer to 7/8"-1" diameter, but it may not really matter.

Tried #12 screws but the original rivet holes are really too big and they don't bite. I drilled them out carefully and didn't enlarge when I removed them - but with the #14 screws you need to use a bit (can't remember what size) that is JUST larger than the existing holes for the #14s to go in tight but not so tight you can't thread them in. 5/8" long #14s would be fine also - the 3/4" almost touch the bottom of the alum. channel.

What I found, and could be part of the issue, is that a number of the holes (5 out of the 14 I think) in the plastic top skin didn't line up very well at all with the holes in the aluminum top bars. So I elongated those holes (maybe by 3/16" on some of them) that didn't line up properly so there was no lateral tension on them and screwed it back together.

Did this last night and it is raining today - will try it out tomorrow - it probably squeaks in all new places now!
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