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Unread 09-21-2012, 07:17 PM   #41
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After that I mounted the solenoid

Here's how I kept things straight! I downloaded all the wiring charts supplied from Scotty and went through it one cable at a time!

Here's a picture looking from the back to the from of the cart. I put the F/R switch supplied by Scotty where it would be and started running the cables
Here's where I'm going to make a suggestion if you are watching my every step throughout this process. BUY YOUR CABLES FROM SCOTTY B! I'm very mechanically and ectrically inclined and I just knew that his cables were going to be worth the price. Boy was I right! His cables are TOP QUALITY and are LABELED!!!!! The cables on your electric buggy are like the artery's between your brand new components and your motor and batteries. If you skimp on the cables you are risking burning up your brand new components and also risk not getting the full potential from you batteries to each piece of your electrical power train, so to speak. DON'T SKIMP ON YOUR CABLES!!!!!!! I just can't say enough about how good the cables that Scotty makes are.
Note: do not use lock nuts on your cables- the plastic insert will eventually get hot and melt!
More pictures of cable connecting 1 by 1
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Unread 09-21-2012, 07:21 PM   #42
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I'm not suggesting that you will need to redo ALL your cables on your cart but I chose to. Mine were crap to say the least. I went to harbor freight and got all the stuff to do this thing right. If I'm gonna do it, I might as well be proud of it!
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Unread 09-21-2012, 07:24 PM   #43
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here's my solenoid after I got it all wired up. I know it looks like a lot of wires but if you follow the wiring chart you will have no issues getting it wired correctly. Think of it as a switch, all the hits on one side and all of the recievers of the power on the other:-)

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Unread 09-21-2012, 07:28 PM   #44
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Next, I wired up all the micro switches on each component
After posting on the forum to find out how to tell which motor stud was which I was told to sand down the motor housing by the studs and voila! It was stamped by each stud what was S1,S2,A1,A2



The junk is starting to add up! Lol
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Unread 09-21-2012, 07:29 PM   #45
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The controller is all wired up! Again, following the chart makes it very do-able

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Unread 09-21-2012, 07:31 PM   #46
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you've gotta make sure you don't mount the throttle assembly too far into the inside of the frame or it'll rub on your battery
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Unread 09-21-2012, 07:36 PM   #47
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Making sense now?



Here's a pic of all my batteries wired up and my first test getting ready to take place: notice my fancy battery holder for my rear two batteries of my 8 total 6v's- they will sit in the bagwell when the body goes back on


Notice how the cables are even color shrink-wrapped for positive and negative

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Unread 09-21-2012, 07:49 PM   #48
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Next was the installation of my voltage reducer. In this picture I have mounted the reducer beside the controller and placed a distribution block on the frame for all the 12v accessories to be tied in to. Note the fuses to ensure safety:-)
I picked these distribution blocks up from Walmart in the car stereo section. They are used for splitting amp power wires but worked perfectly for my project!I originally intended to only use the dust. Block on the positive side by I immediately found a use for it on the negative side too with everything having to come back to the battery post.
I then re-wired my charging receptacle with heavy 4g wire I purchased in 6' rolls from the auto store. I also purchased the new fuse to mount on top of the charging receptacle since mine looked like it came over on the mayflower and I sure didn't want to rush burning up my new setup!!!!
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Unread 09-21-2012, 07:57 PM   #49
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After finishing my conversion I went to the body work. Here I am cleaning the body in preparation of applying the mossy oak graphics wrap
And here goes nothing



I then painted the inside of each body part black with krylon fusion for plastic.
I also painted everything shiny aluminum black and blacked out the roof:-)
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Unread 09-21-2012, 08:02 PM   #50
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Here's a pic of the led volt meter I installed also. No more guessing! I love it. also pictured is my 'lighted' light switch:-)
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