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Unread 12-24-2012, 09:58 PM   #31
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Default Re: The rebuild begins...1992 Club Car DS upgrade

The rear body is going to be a bit of a challenge getting ready to paint. There is a crack on the left rear, below the (soon to be) cutout for the taillights. This body is old, and is going to need a LOT of prep just to get it good enough to paint.


Also, because it is a 1992 body, it has the very small rubber fender flares. You can see one of them in the second photo.

I want to install larger fender flares/mudguards, but they don't make them for 1992 models. 1993 is the first year that the aftermarket flare kits work.

Has anyone had any experience retrofitting the newer flares to an older cart?
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Unread 12-25-2012, 04:12 PM   #32
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Default Re: The rebuild begins...1992 Club Car DS upgrade

I had mocked up the stereo, 12V adapter, and LED wiring to make sure everything worked. Now, I had to disconnect every wire, cut to the correct lengths, solder, crimp, and encase each wire in protective sheathing. You can buy this at Harbor Freight for a couple of dollars, and it is good protection against the elements. I separated the negative wires and encased them in black sheathing, and most of the positive wires in red sheathing. I did run out of red sheathing, and had to complete some of it in black.

I mocked up the headlights, taillights, and rear speakers to make sure that everything works. The speaker wire for all 4 speakers is marine grade and appears to be pretty tough!

Almost done wiring, I still need to cut out the body for the rear tailights, and then start the bodywork.
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File Type: jpg Club Car 2012 rebuild 002.jpg (162.3 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 003.jpg (155.5 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 004.jpg (159.8 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 005.jpg (113.6 KB, 0 views)
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Unread 12-25-2012, 04:21 PM   #33
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Looking good. You've gotten more done than me in the last two days. :)
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Unread 12-25-2012, 05:44 PM   #34
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Default Re: The rebuild begins...1992 Club Car DS upgrade

txbonds,

Thanks! I have had a few days to get some of the wiring done. It takes WAY too long, expecially if you want to do it right.

I have been following your thread. I think that 9PSI in your tires is about right. Amazing that your thump has come back, unless it is (cold) weather based.

I hope that my red paint job looks like yours. I am not expecting too much, due to the age of the body and cowl on this car. However, I'm going to give it a shot based on all of the great information that I have found from this site.
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Unread 12-25-2012, 05:48 PM   #35
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Quote:
Originally Posted by Xact1 View Post
txbonds,

Thanks! I have had a few days to get some of the wiring done. It takes WAY too long, expecially if you want to do it right.

I have been following your thread. I think that 9PSI in your tires is about right. Amazing that your thump has come back, unless it is (cold) weather based.

I hope that my red paint job looks like yours. I am not expecting too much, due to the age of the body and cowl on this car. However, I'm going to give it a shot based on all of the great information that I have found from this site.
That should look great. Mine is the factory club car burgundy color which I think looks pretty good with the buff seats and black trim, but to each their own I guess. :) I'm still planning some more black goodies on mine like diamond rockers and kick plate and maybe a black dash, but over all I am liking the look.

The bumpy tire thing is a mystery to me, but I'm not giving up yet. Going to rotate the tires around some more, and realign the front end to see if it makes any difference. May be cold related as you suggest also, but who knows. Only thing I've managed to get done is working to fix the steering column squeak and to drill and add second bolts into the rear top mounts to stop the movement induced squeak I was having there. Sometimes it seems as though I fix one thing and get 3 new problems though. LOL
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Unread 12-27-2012, 12:28 AM   #36
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Default Re: The rebuild begins...1992 Club Car DS upgrade

I decided to take a shot at the front cowl. It is in better shape than the rear body, and I might learn a few things by practicing on this first, before I spend too much time and effort on the rear body.

The pictures show the cowl mounted on the body, but I prepped and painted it on the garage floor, and then set it up on the cart to dry.

I scuffed the cowl with a maroon scotchbrite pad, then cleaned the cowl and used wax and grease remover prior to some adhesion promoter (rattle can) , and sandable primer spray (rattle can).

First mistake, I didn't do any body work prior to the application of the adhesion promoter and primer. However, the cowl isn't too bad, and I should be able to use some finishing putty to just fill in a few light scratches, then primer again over it.

The pictures always make things look better than they really are

The rear body has a lot of work to be done to it.
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File Type: jpg Club Car 2012 rebuild 001.jpg (135.0 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 002.jpg (113.3 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 003.jpg (129.5 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 006.jpg (120.4 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 007.jpg (140.2 KB, 0 views)
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Unread 12-30-2012, 07:26 PM   #37
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Default Re: The rebuild begins...1992 Club Car DS upgrade

For the front cowl, I cleaned and lightly scuffed it with a maroon scotchbrite pad. Then, I cleaned again with grease and wax remover (available at any auto parts store), applied adhesion promoter, then waited about 20 minutes and applied sandable primer to both the interior and exterior of the cowl. I lightly sanded the primer after 1 day, then applied glazing putty to some of the scratched/damaged areas. Glazing putty is a little easier to sand than bondo, and it was a good choice. I wet sanded several areas, applied more sandable primer, wet sanded again, etc. and just kept working at it slowly.

I left the interior of the cowl painted with the sandable primer, because I think it's a waste of paint to paint the entire cowl with the finish paint. And, I actually like the look of the grey primer under the cowl.

I used Dupli-Color Perfect Match Victory Red over the grey primer. It took about 3 coats, and I was very surprised with the quality of the paint. I then waited another day and applied 3 coats of Dupli-Color Clear Effex clear coat. This should provide a glitter effect to the paint job, but I can't tell in my garage.

All in all a very good start to the paint job!
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File Type: jpg Club Car 2012 rebuild 002.jpg (140.3 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 003.jpg (148.5 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 007.jpg (139.0 KB, 0 views)
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Unread 12-30-2012, 07:34 PM   #38
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Default Re: The rebuild begins...1992 Club Car DS upgrade

looking really sharp. Its all coming together nicely. I've got my new cart/project and still trying to determine what all to do...
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Unread 12-30-2012, 07:36 PM   #39
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Default Re: The rebuild begins...1992 Club Car DS upgrade

The rear body is shot! I almost thought about just giving up and purchasing a new body kit, but after the success of the front cowl, I want to give this a try. Plus, I really like the color!

I spent most of the afternoon just cleaning and lightly scuffing the body. I am going to just mask off the 'Not a Step' treads, and the factory fender flares. They are all just too old and brittle to mess with, and finding the original fender flares is not easy.

I also cut out the rear taillight area with the trusty Dremel tool. SO much easier this way!
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File Type: jpg Club Car 2012 rebuild 005.jpg (91.4 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 006.jpg (113.3 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 004.jpg (87.6 KB, 0 views)
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Unread 12-31-2012, 07:52 PM   #40
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Cleaned and scrubbed the body today. Applied adhesion promoter, waited about 15 minutes, then applied sandable primer.

CAUTION: the next steps require disposable gloves to protect yourself, and some common sense. Give yourself plenty of room to work, and adequate ventilation.

While everything dried, I went to the auto parts store and picked up a small fiberglass repair kit. This kit includes a mesh, and two chemicals that must be mixed and applied with a brush to the mesh on a piece of aluminum foil. This allows the mesh to be soaked with the mixture. I then put the mesh on two spots that had some severe cracks. I let it dry, and it worked great!

Since the repaired areas are on the underside of the cart body, I felt no need to sand or finish them. I will just spray primer of them to cover.

After about an hour I checked the areas, and they are solid as a rock. SO, I may have saved some money on this one.
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File Type: jpg Club Car 2012 rebuild 001.jpg (74.0 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 002.jpg (108.8 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 003.jpg (106.4 KB, 0 views)
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