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Unread 12-31-2012, 08:03 PM   #41
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Now for the floor mat. Mine was only 20+ years old...

There was no saving this one, and I checked prices all over the internet for a new floor mat. WAY TOO expensive for a piece of rubber.

I found, from a forum search, a member that used this website to purchase some mat material:

http://www.allmats.com/site/439205/product/385C

So, I purchased a 4' X 4' section of 'diamond plate style' rubber matting. I think that I spent about $45.00 for it.

I cut out the old CC floor mat and used it as a template. To install the new mat over the pedals, I made a very small slice between the pedals. Then applied duct tape underneath to seal the slice after installation.

I also have enough material left to to make a kick plate for the front of the body, and maybe a few other cosmetic goodies!
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Unread 12-31-2012, 10:53 PM   #42
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Default Re: The rebuild begins...1992 Club Car DS upgrade

That floor mat looks really good Xact. In the link they have black w/ grey outline and black w/ yellow outline. I didn't see an outline on yours at all.. did you trim it off?

I've enjoyed following along on your build, and got some really good ideas too. Thanks!
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Unread 01-01-2013, 09:40 AM   #43
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Default Re: The rebuild begins...1992 Club Car DS upgrade

If you click on 'Top Products' in the link, you can choose a few colors and custom lengths of matting. 4' X 4' is the length that I chose.

I am going to use some of the leftover matting for a kickplate. I will probably glue the matting to a rectangular aluminum strip cut to fit. I am also thinking about lining the bagwell area with it, because I do put golf clubs back there!
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Unread 01-01-2013, 02:52 PM   #44
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Looks great, thanks for the floor mat idea... I have been buying CC mats, now I can stop and save a little $$$.
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Unread 01-01-2013, 03:16 PM   #45
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Default Re: The rebuild begins...1992 Club Car DS upgrade

These are the products that I used for the body repair/prep and paint. I stayed up on New Year's Eve and did sanding and bodywork with a few cold ones.

The body will be acceptable. Certainly not show quality, it is just too rough. However, this will allow me to wait for a couple of years until I change the cart to 48V.
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File Type: jpg Club Car 2012 rebuild 001.jpg (112.0 KB, 0 views)
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Unread 01-01-2013, 03:27 PM   #46
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Default Re: The rebuild begins...1992 Club Car DS upgrade

First coat of red on the body. I am going to let this sit for a day, and then decide where to go from there.

I have (2) small LED lights that I want to mount, maybe in the front of the body to shine on the floor at night. They are the two small round LED's shown on the right of the LED photo.

If so, I need to drill a couple of 3/4 inch holes to mount them, and then wire them into the existing LED switch at the fuse block.

Any other ideas on where I could mount these?
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File Type: jpg Club Car 2012 rebuild 006.jpg (158.0 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 007.jpg (153.4 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 008.jpg (145.3 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 002.jpg (98.7 KB, 0 views)
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Unread 01-06-2013, 03:51 PM   #47
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Default Re: The rebuild begins...1992 Club Car DS upgrade

The rear body is just about finished. I used 3 coats of Duplicolor paint and let it dry for a few days. I then used 3 coats of Duplicolor Clear Effex.

There are two small areas that will require touch up at the rear tailight area, but other than that, it looks OK.

I installed 2 small LED marker lights in the front of the body. I have to wire them up to another switch that I will mount on the dash with the others.

I am very happy with the outcome of the paint job. I would still rather have a new cart body, but this will last for a few years, until I'm ready to go at it again.

I also installed Scottyb's state of charge meter.

Next, I have to bolt the body on, clean up a few wires issues, mask off the rear fender flares and paint them black, and then mount the front and rear lights.
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File Type: jpg Club Car 2012 rebuild 002.jpg (178.7 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 003.jpg (153.3 KB, 0 views)
File Type: jpg Club Car 2012 rebuild 004.jpg (150.6 KB, 0 views)
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Unread 01-06-2013, 04:59 PM   #48
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Default Re: The rebuild begins...1992 Club Car DS upgrade

lOOKING GOOD!!!!

Sorry I didn't see your other post sooner as I was going to suggest seeing if you could mount those LED's under your speaker pods so they shined down on the floor board in front of your feet. Over all it is looking good though.

Another thought if you feel like doing it is possibly paint the "no step" pads with some black plastic paint, or look at the auto store for some sort of restoring cleaner/protector stuff to see if you can get those blackened up. I think having them crisp black like your rims and other trim will make it pop on the red paint. :)

Keep posting pics.
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Unread 01-06-2013, 05:25 PM   #49
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Hey, those 'No Step' pads are shined up! That's how worn out they are, even after a shine>

That is a good idea, there are a few products out there that claim to restore the shine to older plastic products.

I am looking at front brush guards now...
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Unread 01-06-2013, 05:27 PM   #50
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Default Re: The rebuild begins...1992 Club Car DS upgrade

Quote:
Originally Posted by Xact1 View Post
I am looking at front brush guards now...
Sorry, that's my fault.
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