My '92 DS Resoration

Shawn8202 · 04-12-2013, 09:29 PM

Well, last fall I came across a 1992 Club Car DS for $400 and without batteries. I went into this completely clueless and let's just say that this forum has been invaluable! This entire process is ALL NEW for me....but it has been a great excuse to buy new tools.

To date, I have done the following:

1. Body removal and sent off for repair and paint
2. 6" Jakes Lift -much easier than expected.
3. 22" Tires with 10" rims
4. New Rear Shocks
5. New Tie Rod end
6. New Steering wheel and column cover

In progress:
1. 36v-48v conversion kit. Trying to determine which side of the solenoid is+
2. Painting the body and repairing body damage
3. New Batteries (Still not sure what brand)
4. Diamond plate floor, rocker panels and kick panel.
5. New Dash with radio and speakers
6. LED Headlights & Tail lights
7. LED undercarriage lights (Maybe)

I have attached a few pictures and as ALWAYS ... feedback is greatly appreciated.

Xact1 · 04-13-2013, 03:42 PM

Looks good so far. You can purchase Eagle One aluminim cleaner at any auto parts store. It works great with a green scotchbrite pad at shining the aluminum frame.

Make sure that you controller (if that is the black box in one of the pics) is solidly mounted. I would add a support bracket to it if the box rocks back and forth at all.

If you want inexpensive black diamond plate rubber flooring, check out my build thread. If you are going with the real diamond plate, you'll be adding some weight to it unless you can get the thin sheets from a big hardware store.

Shawn8202 · 04-16-2013, 07:53 PM

Well...

- A little more work this evening. I have the controller, solenoid, F&R switch in and hooked up correctly (I think). Some of the new cables were a lot longer than what came off it. I was VERY happy with the fact that each cable was labeled. HUGE HUGE HUGE help!
- After feeling like a total moron and listening to people in the know, the controller mounted VERY easily. (See pics)
- I also purchased and installed a new steering wheel and column cover. (VERY easy)

I am excited to get the body, seat and seat rests back this week. Fresh coat of paint and all new custom seat covers....

I am still on the fence about the canopy. No canopy or yes canopy. To paint or not to paint.

Anyway ... here are some pictures and as always, thoughts and opinions are very welcome.

Shawn8202 · 04-21-2013, 08:29 PM

Hello again ...

Well, aside from some cosmetic items, I am waiting on batteries, a painted body and the newly covered seats.

I am still trying to figure out where the yellow wore goes from the solenoid. I am guess it attaches to a battery terminal but not sure and my pictures do not show the wire.

I am also have an issue with the new receptacle and wires not matching from the 36v to 48v version.

Thoughts ?

Shawn

Shawn8202 · 04-26-2013, 08:04 PM

So I have a new trojan batteries, dash, LED lights and battery meter waiting for me. Should be a good Saturday. Waiting on the 48v to 12v reducer and the body goes back on!

Shawn

jakesnake27 · 04-26-2013, 09:39 PM

Quote:

Originally Posted by Shawn8202

So I have a new trojan batteries, dash, LED lights and battery meter waiting for me. Should be a good Saturday. Waiting on the 48v to 12v reducer and the body goes back on!

Shawn

Have fun tomorrow!

Shawn8202 · 04-27-2013, 09:10 AM

Hey thanks !! Should be interesting but I am also sure I will be posting here =)

Shawn

Shawn8202 · 04-27-2013, 05:25 PM

The dash was a huge piece of cake. Battery trays were polished and under coated.

A did have an issue with the 48V conversion however. I can't seem to find where the issue is, but ScottyB took at least 30 minutes out of his Saturday to help me over the phone. I challenge any business to provide the service he does. THANK YOU!

Scotty: All batteries tested 8.3 -8.6 and the battery pack tested at 50.2

Fom there, I am at your mercy.

Shawn

Shawn8202 · 05-07-2013, 04:54 PM

A little update ...

So, the controller issue ended up being a solenoid issue. A truly long story but its finally running!

I am now finishing the 48v to 12v reducer, CD player/speakers, Battery meter, LED lights under the cart and the headlight install.

With any luck ... the body can go back on tomorrow and I can start showing it off ....

I have attached a few pictures ....

Xact1 · 05-07-2013, 09:25 PM

Lookin' good.

Where did you get the dash kit from? I like it.

04-13-2013, 03:42 PM	#2
Xact1 Gone Wild Join Date: Jun 2009 Location: Binghamton, NY Posts: 384	Re: My '92 DS Resoration Looks good so far. You can purchase Eagle One aluminim cleaner at any auto parts store. It works great with a green scotchbrite pad at shining the aluminum frame. Make sure that you controller (if that is the black box in one of the pics) is solidly mounted. I would add a support bracket to it if the box rocks back and forth at all. If you want inexpensive black diamond plate rubber flooring, check out my build thread. If you are going with the real diamond plate, you'll be adding some weight to it unless you can get the thin sheets from a big hardware store.

04-21-2013, 08:29 PM	#4
Shawn8202 Getting Wild Join Date: Mar 2013 Location: Syracuse, NY Posts: 107	Re: My '92 DS Resoration Hello again ... Well, aside from some cosmetic items, I am waiting on batteries, a painted body and the newly covered seats. I am still trying to figure out where the yellow wore goes from the solenoid. I am guess it attaches to a battery terminal but not sure and my pictures do not show the wire. I am also have an issue with the new receptacle and wires not matching from the 36v to 48v version. Thoughts ? Shawn

04-26-2013, 08:04 PM	#5
Shawn8202 Getting Wild Join Date: Mar 2013 Location: Syracuse, NY Posts: 107	Re: My '92 DS Resoration So I have a new trojan batteries, dash, LED lights and battery meter waiting for me. Should be a good Saturday. Waiting on the 48v to 12v reducer and the body goes back on! Shawn

04-27-2013, 09:10 AM	#7
Shawn8202 Getting Wild Join Date: Mar 2013 Location: Syracuse, NY Posts: 107	Re: My '92 DS Resoration Hey thanks !! Should be interesting but I am also sure I will be posting here =) Shawn

04-27-2013, 05:25 PM	#8
Shawn8202 Getting Wild Join Date: Mar 2013 Location: Syracuse, NY Posts: 107	Re: My '92 DS Resoration The dash was a huge piece of cake. Battery trays were polished and under coated. A did have an issue with the 48V conversion however. I can't seem to find where the issue is, but ScottyB took at least 30 minutes out of his Saturday to help me over the phone. I challenge any business to provide the service he does. THANK YOU! Scotty: All batteries tested 8.3 -8.6 and the battery pack tested at 50.2 Fom there, I am at your mercy. Shawn

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05-07-2013, 09:25 PM	#10
Xact1 Gone Wild Join Date: Jun 2009 Location: Binghamton, NY Posts: 384	Re: My '92 DS Resoration Lookin' good. Where did you get the dash kit from? I like it.