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Old 02-22-2012, 03:15 PM   #1
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Default Upgrading a 1999 Club Car DS to 48v

Hello everyone. I am upgrading my trusty 1999 Club Car DS 36v resistor cart, and will be replacing everything but the frame. I'll be posting pictures as the parts show up, but based on the comments I gathered from this site, this is what I've ordered so far:

- Plum Quick:
Rattlesnake 2 48v motor (29-31 mph)

- Carts Unlimited:
GE FSIP 700 Amp Controller
400 Amp Super Duty Solenoid
Modified Potentiometer
2G cable set
Heavy Duty F&R Switch

-Jake's Lifts
6" Spindle Lift Kit
12" Yellow Jacket Wheels w/tires, approx 22" (and a wheelbase extension plate)
HD Rear Leaf Spring Kit

- Still left to order:
Six 8v T-875 Trojan batteries
48v Charger
Roof and Roof Supports
Seats
Other bits and pieces

I'll have a lot of questions as I go, but my first questions involve seats/roof. I want to put in custom seats, and a better roof and rear roof supports. My 1999 Club Car DS has the alumium roof supports, and the flimsy plastic roof. I want to put in a 2000+ year style DS roof and black roof supports. Will the 2000+ roof supports fit my 1999 DS? Does anyone know a good place to order?

As a side note, I also want to replace the seats to a single-back format, if that affects your thinking about the 2000+ roof.
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Old 02-22-2012, 06:59 PM   #2
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Default Re: Upgrading a 1999 Club Car DS to 48v

I went topless on my 95 DS but I did find a seat, basked and bench from the 2000.5+ for like $50.00 from a used golf cart dealer. It was in his junk pile and I just asked what he wanted for them. Bought some covers and reblacked the black parts with Bondo black restord and they looked great. Heres a pic and I know I put the back rest on upside down because I was excited to get this Frankenstine alive but have since flipped it! Don't mind the pesky turkey hen! The top should work fine with the new style seats.
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Old 02-22-2012, 07:04 PM   #3
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Default Re: Upgrading a 1999 Club Car DS to 48v

Sorry, pics didn't attach.
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Old 02-23-2012, 01:59 PM   #4
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Default Re: Upgrading a 1999 Club Car DS to 48v

Thanks for the info, Colbyntx. Here is a picture of my rear strut mount. Just one last confirmation, the roof struts for a 2000+ DS should match up with my 1999 DS?

Here is one source for a 2000+ roof and struts ($439):
https://www.3rsalesandservice.com/ca...e/NIV13746.htm

That roof looks okay, but not really all that great. Anybody know of a place selling a stouter roof?
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Old 02-24-2012, 06:38 AM   #5
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Default Re: Upgrading a 1999 Club Car DS to 48v

Be careful . . make sure you know for sure because in 2000, they changed the design of the seatback and it may not be a direct fit on a 99 . . . wait for someone that knows for sure before ordering . . .
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Old 02-24-2012, 11:56 PM   #6
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Default Re: Upgrading a 1999 Club Car DS to 48v

Got a bunch of boxes from Jake's. See photos to see the 6" Spindle Lift, HD Leaf Springs, Hydraulic Disc Brakes, and sweet rims and tires. Also a photo of the cart sitting ready in my shop.

Oh, also a picture of the 700 Amp controller from Carts Unlimited.
Attached Images
File Type: jpg tableOfParts1.jpg (74.1 KB, 15 views)
File Type: jpg newWheels1.jpg (68.3 KB, 14 views)
File Type: jpg liftParts1.jpg (61.1 KB, 14 views)
File Type: jpg controller1.jpg (30.2 KB, 17 views)
File Type: jpg cartShop1.jpg (79.9 KB, 24 views)
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Old 02-25-2012, 06:36 AM   #7
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Default Re: Upgrading a 1999 Club Car DS to 48v

I want your pole barn . . .
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Old 02-25-2012, 07:49 AM   #8
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Default Re: Upgrading a 1999 Club Car DS to 48v

That looks like a great project!
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Old 02-25-2012, 10:55 AM   #9
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Default Re: Upgrading a 1999 Club Car DS to 48v

this just isn,t right................lolol........................ .....
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Old 02-25-2012, 07:53 PM   #10
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Default Re: Upgrading a 1999 Club Car DS to 48v

Another box in the mail, solenoid, pot, cables, F&R switch, mounting brackets from Carts Unlimited. Also came with nice looking wiring diagram, which will come in handy since I tore out most of the old wiring with a carefree attitude and minimal notes.

Started the demolition of the cart, removed roof, seats, most of the guts. Those batteries are HEAVY, holy cow. One of the screws holding on the rear body is rusted like crazy, so it's saturated with PB Blaster. That's it for today.
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File Type: jpg topless1.jpg (63.3 KB, 12 views)
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