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Unread 10-23-2012, 09:51 AM   #11
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Removed the stock motor to send to Plumb Quick for a Bandit upgrade.

Let me say now that this site has been invaluable in my rebuild so far. I did a 'search' on motor replacement and read all that I could prior to attempting to remove the motor. From what I have read (and seen, thanks to the great photos by forum members), the motors have the tendency to bind at the input spline and the female end of the motor.

Mine was no different. With the motor bolts removed, I could pry the motor back and forth, but couldn't remove it. I managed to get a large enough opening to spray PB Blaster, with an extension nozzle, in at the spline. I let it sit overnight. In the morning I was able to get the casing off, but the motor itself was still stuck to the spline.

I removed the right reat tire, and used a large rubber mallet along with a wooden extension block, to pound the end of the motor back towards the gearbox. Then, I would try to work it back and forth. After a few tries, and some more PB Blaster, it came off.

I am certain that I could not have done this without assistance from all those who have gone thru this before. I highly recommend that those who browse this forum use the 'search' function prior to tackling their project.
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Unread 11-08-2012, 01:13 PM   #12
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Got some new parts in today. The Plum Quick Bandit motor (looks great), a Blue Sea 5025 6 circuit fuse block, some red and black 10 gauge primary and ground wire for the fuse block, and 50 feet of marine grade speaker wire.

I took the body off this morning. Of every nut and bolt that I have taken off on this cart, the hardest by far were the body hardware. Not the steering wheel nut, not the leaf spring bolts, but the body hardware!

Every bolt was rusted closed. I had to hacksaw several of the bolt heads off.

With the rear body off, I can see that it is a little tired after 20+ years. I have to work with what I have, so I need to get the front cowl off today, and then push the cart out in the driveway this weekend for a gentle wash (yeah, I'm going to wrap everything electronic in garbage bags).
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Last edited by Xact1; 11-08-2012 at 01:17 PM.. Reason: included photos
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Unread 11-09-2012, 07:43 AM   #13
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Default Re: The rebuild begins...1992 Club Car DS upgrade

. . . now that body is off, inspect EVERY aluminum weld for cracks . . .
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Unread 11-11-2012, 10:25 PM   #14
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Sunday was a nice day in upstate NY. I rolled the cart out and started cleaning it . Also took both the front cowl, rear section, and top section outside and washed them as well.

20+ years of grime does not give up easily. I spent about 5 hours cleaning everything to get it to this point.

I will be moving the Alltrax controller, installing a 12V battery for the lights, radio, and other small accessories.

More pics to follow
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Last edited by Xact1; 11-11-2012 at 10:46 PM.. Reason: added text
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Unread 11-13-2012, 11:44 PM   #15
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Got a little bit done today. I installed the Plum Quick 36V motor. Before installation I applied some anti seize compound to the spline.

I also removed the Alltrax 4845 Controller. I plan on installing a 12V battery in it's spot to power my lights and radio. Not sure where to put the Alltrax Controller and the 36V Solenoid. The solenoid is currently in front of the batteries. I will move it up with the Controller, just not sure where yet.

I also tested the Curtis PB6 throttle box that I had installed a few years ago. It is a 0-5K ohm unit and measured 5.22K ohms at full stroke.

I marked every wire with a label to help me to re-install all easier. The pics show that it pretty much looks like a wreck right now!

I'm thinking about removing the batteries and applying Herculiner to the battery tray area. I had cleaned this area a few years ago, and installed new aluminum supports where needed. It does look like a few years have worn on the tray area. What do you think?
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Unread 11-15-2012, 02:20 PM   #16
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Default Re: The rebuild begins...1992 Club Car DS upgrade

I cleaned up the battery area again. Instead of using Herculiner, I decided to use a 3M rubber undercoating spray.

I installed Scottyb's throttle conversion kit. It takes some time to get the correct throw from the pedal rod, to the bell crank, and then to the PB-6 arm. With my 1992 cart, I ended up using an additional washer under each 'spacer' that Scottyb provides. WIth the bell crank at rest, the pedal rod just misses the bottom of the floorboard. At full pedal depressed, the pedal rod just misses the lower frame. The PB-6 arm is just barely short of a full throw, just missing the hard stop. At full pedal depressed, I show 5.42K ohms.
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Unread 11-15-2012, 10:09 PM   #17
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Did you are are you going to install front brakes?
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Unread 11-15-2012, 10:24 PM   #18
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Quote:
Originally Posted by oconnorb View Post
Did you are are you going to install front brakes?
oconnorb, I hadn't really thought about it. My cart originally had a top speed of 14mph. With the PQ Bandit Motor (still at 36V), the lift kit, and Scottyb's cables, along with the 400 amp Alltrax Controller, I am hoping for around 17mph. That would be enough for now. Once the batteries need to be replaced, I will then upgrade to (6) 8V batteries and go to 48V. THEN, I might have enough speed to need front brakes. Several forum members have posted threads about their front brake installs.
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Unread 11-18-2012, 05:54 PM   #19
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Today I did a mock up of the battery meter (thank you Scottyb) and the stereo. I purchased a Kenwood KMR-350 marine unit. After looking at several options, including purchasing a new dash, I just decided to buy a universal stereo mount (about $11.00 including shipping on E-bay). My plans are to take the meter and stereo back out, and paint the dash hammered black. I'm hoping that this will hide some of the flaws (old cigarette butt scars, etc) from years of use. PS> I do not smoke; the golf cart was previously a fleet vehicle.

I also purchased a 12V marine battery with a $50.00 off coupon from an auto parts store. I want to use this to power my 12V lights, radio, accessory outlet, etc. and wanted the battery pack to be separated from my 12V requirements. I have a couple of options on where to mount the battery:

1. Behind the battery pack. This would be OK, but a PITA to get out when it needs to be changed. Also, I would have to fabricate brackets to facilitate the proper angle for servicing.

2. In the bagwell. Not really an option that I like, because I actually use the golf cart for golfing, and like to put my clubs where they were originally designed to go.

3. In the basket behind the seats. I currently only use the basket to put a cooler in for a few cold ones I could drop a battery box right in there, install the battery, and be done with it. It would also make servicing the 12V battery very easy.

OPINIONS PLEASE!
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Unread 11-18-2012, 10:32 PM   #20
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Here is a mock up of what the 12V battery would look like just behind the standard (6) 6V battery pack. I would prefer to mount the 12V battery here, because it hides it out of the way. Replacement would involve removing the middle batteries in order to get at it.

The 12V battery is a group 24 deep cycle marine battery. Here's my question:

Do you think that the angle (slope) of the battery will have any affect on the performance of the battery? I would assume that marine batteries take a lot of abuse in this regards.

Again, this is only a mock up and can be changed.
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