Remove and replace TXT body

Sadiedog

I have gone through the sticky on this issue which was very helpful!!

I would welcome input from anyone who has done this and advise how difficult this job was? I think this would be fun to do but not sure if it is worth it or just have the dealer do it as I am looking to buy a 2004 or 2005 PDS cart. The dealer wants $500 to put a new body on the cart because I will buy the cart from them. However, colors are limited.

Otherwise I think I can buy a new or painted body for $350 (from another dealer) but would have more of a choice of colors, however, I would need to do the removal and install myself.

Thanks for the input.

BGW

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kgsc

Job is not too bad. Order the body rivet kit for $15, get a pneumatic rivet gun, a drill with a 3/16 bit and proceed. The roof and hardware need to come off. Keep track of where things go. Rear basket/seat assembly come off. Front badge comes off. Sill and plastic rocker panels come off. Now all the rivets that need to go away should be visible. When you get the rear body rivets gone lift the front part and it will "roll" out of the bumper. IMO the hardest part is getting the cowl back on. Two people helps. Get it in position and make sure all the holes line up before you start popping rivets. Put the center one in and make sure it held. Hold the rest tight and continue.. Easy after that..

mattadata

Is not difficult....just takes a little time. I didn't know what a rivet was before I started. I bought the EZGO rivet kit and a hand held rivet gun from Harbor Freight. Just make sure you get the larger gun that can handle 1/4'' rivets.

Some folks replace the rivets with nuts/bolts. I only did that on the key switch plate. It also gives you a chance to clean areas of the frame you can't reach when the body is on.

Note that the rivet kit usually does not come with the 'Christmas Tree plastic push rivets' Those are the plastic ones in the bag well. Most of the time you can get them out without breaking them, but a few of them broke when I was trying to remove them.

interstate

Drill bits break easily on this job, have some spares on hand to keep progress moving. For the price, I bought a spare rivet set, too, and boy am I glad I did.

That air rivet gun has been handy for many other projects as a great bonus. I love it when investments in tools keep paying for themselves.

paintdude96

and once you get the body off u can bring it to me and ill paint it any color u want any color

kgsc

I bought the $30 air gun from HF and have never regretted it.. It will not do the big 1/4 rivets for the lower body but I don't use those anyway.. Either a bolt or a standard dash rivet with a washer..

scottyb

I think the average guy is going to be a little surprised how involved this project is, might well be worth paying the dealer $150 for their expertise, tools, materials.
But if you do decide to do this on your own get a couple of cans of the Krylon for plastic black spray paint and repaint the dash & all the plastic before you put it back on for best results.

paintdude96

yeah I bolted my rocker guard on http://www.buggiesgonewild.com/pictu...ictureid=22761

paintdude96

Sir Nuke

SasdieDog....as others have mentioned, its actually pretty easy. However, we don't know your mechanical abilities and what your "Toolbox" consists of. some have suggested a pneumatic pop rivet gun, I personally have a regular manual one that works just fine and only cost about $10. the job will consists of taking off the roof, then its supports, then the seat(s), and unplugging the lights (if you have them).

after the above is done.....start drilling each rivet and removing the few bolts/screws you may encounter..... and in about an hour or so your cart will look like this.


Body's Off 1A.jpg

Body's Off 2A.jpg

Body's Off A.jpg