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Unread 03-23-2012, 09:43 AM   #71
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Default Re: Upgrading a 1999 Club Car DS to 48v

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Originally Posted by scottyb View Post
All the wire in the cart needs to be automotive type wire. Household wire is high voltage/low amperage stuff. The wire requirements for DC is different than AC because of the high amperage/low voltage.
Actually don't mean to correct anyone that helps so much, but that is not a true statement. An example a number 12 stranded wire will only hold 20 amps in your house due to the 120volts but at 12 vdc it will work at 60 amps. Now with the way current goes through wires I wouldn't use solid wire in automotive application. Of course there are numerous things that can effect the ampacity of any given wire. IE temp, length, etc

Should have added just think of the best battery cables you can make come from welding cables which are used in AC
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Unread 03-23-2012, 10:10 AM   #72
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Default Re: Upgrading a 1999 Club Car DS to 48v

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Originally Posted by 89GatorClub View Post
Actually don't mean to correct anyone that helps so much, but that is not a true statement. An example a number 12 stranded wire will only hold 20 amps in your house due to the 120volts but at 12 vdc it will work at 60 amps. Now with the way current goes through wires I wouldn't use solid wire in automotive application. Of course there are numerous things that can effect the ampacity of any given wire. IE temp, length, etc

Should have added just think of the best battery cables you can make come from welding cables which are used in AC
2 More important differences in household AC wire and DC automotive wire are jacketing and flexibility.
Generally AC wire is not jacketed to withstand acid & fuel as it may be exposed to in a vehicle. There are exceptions.... such as THNN wire, or is it THHN or THWN ?? I forget, it's been a while since I needed that info.
Second there is the ability of a wire to handle vibration. Automotive wire is designed to handle flexing due to vibrations such as in a moving vehicle.
Use of house wire may result in fatigue failures at rigid connection points. I hope this helps. if not, that's okay too
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Unread 03-23-2012, 12:25 PM   #73
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Default Re: Upgrading a 1999 Club Car DS to 48v

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Originally Posted by scottyb View Post
2 More important differences in household AC wire and DC automotive wire are jacketing and flexibility.
Generally AC wire is not jacketed to withstand acid & fuel as it may be exposed to in a vehicle. There are exceptions.... such as THNN wire, or is it THHN or THWN ?? I forget, it's been a while since I needed that info.
Second there is the ability of a wire to handle vibration. Automotive wire is designed to handle flexing due to vibrations such as in a moving vehicle.
Use of house wire may result in fatigue failures at rigid connection points. I hope this helps. if not, that's okay too
Yeah THHN (Thermoplastic High Heat Resistant Nylon Coated) and THWN (Thermoplastic Heat and Water Resistant Nylon Coated) are the standard for wiring in a home and business now. This is a good discussion to have but probably in the wrong thread. Vibration is the reason I said I wouldn't use solid wire and would use stranded. Me personally do not like the cheap wire you would buy at Autozone , Discount Auto, or even Napa.

The reasons above are a better case for the correct wire, because amps are amps weather AC or DC is what I was trying to say
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Unread 03-23-2012, 12:36 PM   #74
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Default Re: Upgrading a 1999 Club Car DS to 48v

Agreed.
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Unread 03-23-2012, 02:47 PM   #75
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Default Re: Upgrading a 1999 Club Car DS to 48v

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The difference in wire being "stiff" or "flexible" is not because its building wire. It has to do if the wire is solid or stranded. (Solid is without the insulation 1 wire where Stranded uses multiple stands to equal the same rating for the wire) So, solid wire is stiff compared to is counter part stranded wire.
I understand, but there is stranded wire used in the construction trade. I didnt think it was solid wire.
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Unread 04-04-2012, 05:39 PM   #76
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Default Re: Upgrading a 1999 Club Car DS to 48v

I think the new paint job speaks for itself, very under-stated.
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Unread 04-04-2012, 08:45 PM   #77
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Default Re: Upgrading a 1999 Club Car DS to 48v

Holy SmokeS!
That looks good ~ I'm partial to flames
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Unread 04-08-2012, 02:29 AM   #78
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Default Re: Upgrading a 1999 Club Car DS to 48v

Still working on the wiring, and it is going pretty well. Also took off the old steering wheel, and started fitting the new dash, one of those Strech Plastic carbon-fiber look jobs. Had to drill a hole for the volume control for my Poly Planar MP3 amp. You can see the amp mounted in one of the pictures. I painted the aluminum parts around the dash areas, since the raw aluminum looked odd against all the black of the dash, and my now-painted aluminum cowl piece.

Still need to drill a hole for a headlight switch, and drill a rectangular hole for the digital voltage meter.
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Unread 04-08-2012, 06:31 AM   #79
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Default Re: Upgrading a 1999 Club Car DS to 48v

Looks like you are movin right along. What an upgrade that will be man, you are going to have a slick ride put together.
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Unread 04-18-2012, 11:12 PM   #80
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Default Re: Upgrading a 1999 Club Car DS to 48v

This weekend, I finished the secondary wiring. This includes the horn, the voltage meter, the MP3 amp's volume control and input jack, the 12V power point. Then I got my courage up to start connecting the batteries and the solenoid and the controller. And the F/R switch and the charger receptacle.

At some point, there were no more cables to connect, no more wires to triple check. I stuck the key in the ignition and stepped back. Turned the key. The voltage meter came on! I stood around for awhile (did I mention I jacked up the back end before wiring any big cables), and finally touched the accelerator. The big solenoid clicked LOUD, scared the hoo out of me. Then the wheels started spinning! I only got the pedal down a few inches before I backed off, they were going so fast. Later on, I hooked up my new charger, and charged the new Trojans overnight.

Tonight I screwed the new headlights into the body and put the front end on the cart. Looks pretty nice.
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