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Unread 01-25-2009, 08:28 AM   #61
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Default Re: Brought home an Ike casualty today

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CCJohn,
Your rebuild has been nothing but professional,...I've learned alot off this thread. Keep up the good work.
THANKS!!!

When it comes to a project like this, trying to do things half-assed WILL come back and bite you in a very big way.. If something is worth spending my time & money on, it's worth doing RIGHT the first time...
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Unread 01-26-2009, 10:26 AM   #62
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Default Re: Brought home an Ike casualty today

Well "Ike" can see to get home at night after this weekend..

Installed a factory light kit and a LED "gas" gauge so I can quit carrying a voltmeter around.. The worst part of the light kit install is cutting the holes for the headlights!! At least I got to practice on this old cowl before I get the body that I'm gonna paint..
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Unread 01-26-2009, 05:49 PM   #63
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Default Re: Brought home an Ike casualty today

Just put the finishing touches on a temporary windshield for Ike.. I was getting tired of picking skeeters out of my teeth.. It ain't show quality, but it'll do until I get a set of supports for the '02 top I picked up on Craigslist..

The old windshield frame had the clips but no windshield.. I trotted down to Lowe's and picked up a 24"x48"x3/16" sheet of clear Acrylic.. Trimmed it to fit the width, and radiused the corners.. Lopped off the top of the old frame, and attached it with the old clips.. It's amazing how much wind a "shorty" windshield blocks!!
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Unread 01-26-2009, 06:07 PM   #64
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Default Re: Brought home an Ike casualty today

Jon nice job on the windshield, giving me some ideas for HAHA
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Unread 01-26-2009, 06:21 PM   #65
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Default Re: Brought home an Ike casualty today

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Originally Posted by CC-John View Post
Just put the finishing touches on a temporary windshield for Ike.. I was getting tired of picking skeeters out of my teeth.. It ain't show quality, but it'll do until I get a set of supports for the '02 top I picked up on Craigslist..

The old windshield frame had the clips but no windshield.. I trotted down to Lowe's and picked up a 24"x48"x3/16" sheet of clear Acrylic.. Trimmed it to fit the width, and radiused the corners.. Lopped off the top of the old frame, and attached it with the old clips.. It's amazing how much wind a "shorty" windshield blocks!!
What did you use to cut and trim with??
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Unread 01-26-2009, 06:52 PM   #66
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Default Re: Brought home an Ike casualty today

That's what Tom did to make me a windshield... He calls it a anti-whine device because I whine so much when it's cold. Made so it comes off and on in a couple of minutes. I love it.
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Unread 01-26-2009, 06:53 PM   #67
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Default Re: Brought home an Ike casualty today

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What did you use to cut and trim with??
I used a Rotozip with a plastic cutting bit.. Clamped an aluminum straightedge along the edge I needed to cut.. I clamped a old wire spool under the corners to get the radius I was looking for.. After making the cuts, I dressed all the edges with a laminate file..

BTW, the Rotozip makes short work of doing light cutouts in cart bodies..
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Unread 01-26-2009, 07:00 PM   #68
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Default Re: Brought home an Ike casualty today

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I used a Rotozip with a plastic cutting bit.. Clamped an aluminum straightedge along the edge I needed to cut.. I clamped a old wire spool under the corners to get the radius I was looking for.. After making the cuts, I dressed all the edges with a laminate file..

BTW, the Rotozip makes short work of doing light cutouts in cart bodies..
Yep I love my rotozip. Did my head lights and tail lights. Was afraid it would melt the lexan?
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Unread 01-26-2009, 10:32 PM   #69
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Default Re: Brought home an Ike casualty today

Well Ike survived his first major road trip...

The GF & I drove to the local Chinese restaurant for dinner.. He got us there and back home with power to spare... It was an 8 mile round trip averaging 20 MPH.. Pack voltage before I plugged in the charger was hovering around 48.5/48.6 volts.. I guess those old Interstates are tougher than I thought!! This was the first major deep cycle these batteries have seen since the cart was submerged during the hurricane.. They seem to have passed the first test..
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Unread 01-26-2009, 10:36 PM   #70
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Default Re: Brought home an Ike casualty today

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Yep I love my rotozip. Did my head lights and tail lights. Was afraid it would melt the lexan?
Ive learned the trick to cutting plastics with rotary tools is to use the lowest available speed, and a new sharp bit.. A slightly dull bit, or too high a bit speed will melt the plastic and fuse the cut back together..
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