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Unread 10-25-2009, 07:41 PM   #31
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Default Re: 1999 Club Car upgrade options

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Originally Posted by flynvest View Post
Hey Impalass88, thanks for the note. I appreciate the humor. Be careful though, the toggle switch may be a cool little test to see how the cart handles the instant acceleration. Figure I'll need seatbelts next?
May I suggest a wheelie bar too?
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Unread 10-25-2009, 10:24 PM   #32
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Default Re: 1999 Club Car upgrade options

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Originally Posted by flynvest View Post
Hey Impalass88, thanks for the note. I appreciate the humor. Be careful though, the toggle switch may be a cool little test to see how the cart handles the instant acceleration. Figure I'll need seatbelts next?
I would like to thank you for your testing. I just got a cart and trying to see what I could do to improve run time. I plane to use it in my maintenance department. Lots of hill. How much did the conversion and motor cost?
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Unread 10-25-2009, 11:11 PM   #33
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Default Re: 1999 Club Car upgrade options

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Originally Posted by SKYENERGY View Post
I would like to thank you for your testing. I just got a cart and trying to see what I could do to improve run time. I plane to use it in my maintenance department. Lots of hill. How much did the conversion and motor cost?
This is my list of costs. Yours may vary because I went extreme with a 650 amp programmable controller. You could just go with a non-programmable 400 amp if your looking to save money.
AllTrax AXE 650 amp controller $600.00
Curtis PB-6 pot box (throttle control) $90.00
Albright Heavy Duty Solenoid 400 amp $75.00 (I got a really good deal on this) typical $150.00 - $180.00
25 feet #2 welding cable $35.00
Lugs for Cable $25.00
48 volt Charger $250.00
6 new 8 volt US Batteries $650.00

I used the existing motor and forward/reverse switch (the one in the 1991 Club Car DS I have is a very stout piece). This is not an in-expensive conversion, but well worth the money. I am later on going to upgrade to a D&D Motor Systems motor (approx. $500.00). If you need more info just let me know. I can provide you with links to the best parts prices (I shopped around alot), wiring schematics, and any other info you need.
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Unread 10-25-2009, 11:24 PM   #34
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Default Re: 1999 Club Car upgrade options

$1725 for the upgrade? And how much was the original 36v cart?
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Unread 10-26-2009, 11:50 AM   #35
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Default Re: 1999 Club Car upgrade options

Did anyone notice the fact that the seat has been on fire, fire man, FIRE, dont U get it.

Change the name of this thread to "Never Do Anything This stupid"
I just don't want some newbie to get ahold of this and fry a kid !
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Unread 10-26-2009, 12:15 PM   #36
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Default Re: 1999 Club Car upgrade options

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Originally Posted by gmorrison View Post
Did anyone notice the fact that the seat has been on fire, fire man, FIRE, dont U get it.

Change the name of this thread to "Never Do Anything This stupid"
I just don't want some newbie to get ahold of this and fry a kid !
AS a Newbie to the site. I found this to be a good thread. It has pushed me into converting my cart. All though a person who has electrical experience would know that you should not over current the resisters that came with the cart.(remember your OHM's Law) I know you can change them out with what is used in fork lifts. They will handle 100amps at 48volts. I do not recommend doing anything if you have never do it before. DC voltage is very DANGERACE. When batteries are charging and discharging. They produce hydrogen. Add a spark and BOOM. I have had this experience with the large set in my solar home. If you ground your self to your batteries in the wrong way. You will not be able to let go. It is not like AC that pulses and gives you a millisecond to let go. So, after going on about safety. I sure hope that anyone who plays with batteries knows that they can kill. There should be something posted about this.
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Unread 10-26-2009, 12:19 PM   #37
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Default Re: 1999 Club Car upgrade options

Quote:
Originally Posted by impalass88 View Post
This is my list of costs. Yours may vary because I went extreme with a 650 amp programmable controller. You could just go with a non-programmable 400 amp if your looking to save money.
AllTrax AXE 650 amp controller $600.00
Curtis PB-6 pot box (throttle control) $90.00
Albright Heavy Duty Solenoid 400 amp $75.00 (I got a really good deal on this) typical $150.00 - $180.00
25 feet #2 welding cable $35.00
Lugs for Cable $25.00
48 volt Charger $250.00
6 new 8 volt US Batteries $650.00

I used the existing motor and forward/reverse switch (the one in the 1991 Club Car DS I have is a very stout piece). This is not an in-expensive conversion, but well worth the money. I am later on going to upgrade to a D&D Motor Systems motor (approx. $500.00). If you need more info just let me know. I can provide you with links to the best parts prices (I shopped around alot), wiring schematics, and any other info you need.
Thank you for the great info. I got my cart for free. so, the money spent for a converting seems reasonable.
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Unread 10-26-2009, 12:23 PM   #38
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Default Re: 1999 Club Car upgrade options

Okay.....nuff said..... this was supposed to be an entertaining little endeavor but evidently it's not. My costs are about the same for the changeover. I am using an Alltrax 4855 with a DD motor ES-81. 'Bout the same in every other way. I didn't get into this for a golf cart to just play golf in or I could have left the original alone. The original 36 volt cart cost me $200.00 in good condition. I began this thread to see what I could do with a golf cart. I like to tinker, and this is a hobby to relieve stress and just enjoy reconditioning and improving the cart. I could have chosen dirt bikes, Harleys, muscle cars, whatever.... It's not the money (well, I do have to budget) but it's cheaper than therapy and it's a fun learning investment. My son and I are enjoying the experiment. We are careful and safe. Maybe the pictures of someones else's debacle are proof of what can happen. Gee, if I take my correctly lifted and performance enhanced EZ Go down a hill and turn too sharp I may roll over myself and get hurt. Should I not drive down hills because there is the potential of getting hurt? I don't feel I'm in mortal danger with a golf cart. Common sense just ain't what it used to be. I'm sure the first few nascar mechanics were ridiculed for their engine enhancements, but look what came out of the testing. I have watched a 36 volt battery literally explode just because someone carelessly let a wire spark across both poles. The battery had just been charging and had enough hydrogen built up to blow the entire top of the battery off. No, really, it did, and the guy was hurt. Maybe, done right, there is a way to improve the cart AND be frugal, AND be safe with it. There.....done..... my battery is well ventilated....
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Unread 10-26-2009, 12:50 PM   #39
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Default Re: 1999 Club Car upgrade options

Look "flyinvest" I'm not bashing U or anyone else here , I just don't want someone to search this thread and read the first page of the post and think this is the answer.
You are doing all the correct things to conduct a 36 Volt Upgrade test !!! and should be congratulated for your quest for knowledge and taking one for the team
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Unread 10-26-2009, 10:00 PM   #40
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Default Re: 1999 Club Car upgrade options

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Originally Posted by scottyb View Post
$1725 for the upgrade? And how much was the original 36v cart?
I paid $900.00 for the original cart. It was in great shape. I sold the 6 volt batteries for $35.00 each (3 1/2 year old Interstates in okay condition) to the company I work for to use in an aerial work platform. The conversion really only cost around $1100.00 because the batteries were going to need to be replaced soon, runtime was suffering. The batteries hold a solid charge but discharge rate was suffering. They will work good in the lifts because they are far less demanding on the batteries than a golf cart. So i look at it this way, the batteries should not be counted in the upgrade cost in my case.

Does this sound more reasonable?
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