Picked up another cart

BobBoyce

Thanks to jnuebig, I'm on the way home with an old 2008 cart that had been partsed out. He had found it at a dealer in Houma LA. It has a bad wiring harness, and is missing the controller, batteries, motor brake, and a headlight. The dealer thought it was an RXV (it is the same electrically) but I found it to be a Shuttle 2X2. The main difference is in the heavier rear suspension and the factory rear seat and an extended roof that covers the rear passengers. I'll use parts from my wrecked 2012 RXV to get it going. I'm on my phone and it apparently will not let me upload the photo, will post it later.

Bob

BGW

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BobBoyce

Here is the photo the dealer took.

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jneubig

Glad you were able to get it. I actually thought about buying it and using the back end to build a trailer to tow behind mine and selling off the extra pieces to cover the expense.

BobBoyce

I actually have parts to do that if you want to. A frame and axle, and a rear RXV body.

I went out and took some more photos, and I noticed that the rear seat footrest assembly is welded to the frame, not bolted. The pics are a side view, the serial number sticker on the dash frame over the driver side front wheel, and the battery compartment.

Bob

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jneubig

I'll let you know if I decide. I actually have a little lightweight fold up trailer. I'm probably just going to drop a body and seat on it and call it done. I have a couple TXT bodies laying around. It's not something I would use often at all, maybe once a year.

BobBoyce

Well, the 2008 RXV Shuttle 2+2 is now finished. I had removed and gone through the main harness weeks ago, converting it over to use the Curtis controller. It required a lot of cleaning, but no problems were found. The pedal assemblies had to be gone through, cleaned and lubed, and new position encoders were installed. I had bought new brake and throttle switches, but the originals were ok so I reused them.

I dismantled the Shuttle 2+2 down to the frame on sunday, 2/19/2017. Everything below the battery box level was coated in grey mud studded with lots of snail shells. It looked like a flood cart. Thank goodness, the motor was not submerged. I installed a brand new motor brake and capped the electrical socket on it.

My friend Thomas that has the auto body shop in Biscoe NC showed up to help. He brought all of the parts from my wrecked 2012 RXV. While I was away at the doctors yesterday, 2/20/2017, Thomas cleaned everything he could. By the time I made it back home, everything was dry and ready to put back together. We only had about 5 hours of daylight left, so we rushed through it.

I installed the repaired Curtis controller assembly from my 2012 RXV and installed the main harness. While I was wiring the controller and batteries, Thomas installed the charge port and pedal assemblies. I put in the keyswitch and SOC meter, and mounted the dash. At this point, we jacked up the rear and blocked it up so I could test operation. The only hiccup experienced was I had to clear the previously stored trouble codes. No new errors were found and every test passed. The cart was only run in that state, just to test the operation of the controller and motor in both forward and reverse. Having success, we set our sights on finishing assembly. We put on the rear seats, roof supports, roof, cowl, pedal cover, floor mat, rocker panels, and rear view mirror. The mosquitos were getting aggressive, so I took some pictures and we stopped for the evening. The only things left to be done are to torque the rear hub nuts and to take her off of the trailer.

Bob

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	RXV Shuttle 2+2 Front.jpg (802.2 KB, 0 views)
	RXV Shuttle 2+2 Rear.jpg (803.8 KB, 0 views)
	Side Decal.jpg (144.6 KB, 0 views)
	RXV Shuttle 2+2 Controller.jpg (239.6 KB, 0 views)
	RXV Shuttle 2+2 Battery Compartment.jpg (281.2 KB, 0 views)

usgicollector

Looking good Bob...

Thanks for the pictures...

BobBoyce

I had a bit more work to do. Besides the rear hubs being a tad bit loose, the rear differential was binding in turns and clunking. I suspected water in the rear end, so I dropped the differential cover and drained the oil. No water, but someone had overfilled it, and obviously had put the wrong fluid in it. It was clean, but deep red in color, and smelled really strongly of solvent. It reminded me of transmission fluid mixed with something else. There was no sludge or metal particles. Everything looked like it had been cleaned recently. The differential cover had been put on with no gasket and a clear silicon sealer.

I cleaned the mating surfaces and applied Permatex Ultra Synthetic Gasket Maker. I lifted the front of the cart to level the mating surfaces, poured 8 oz of Castrol synthetic differential oil and 2 oz of limited slip additive into the differential cover, and bolted it on. Afterwards, I tightened up the hub nuts, then took it for about 1/2 mile drive down the road, then back. All is good now.

It's back on the charger. I'll be taking it easy with this cart. I'm leaving it in Profile 4 with the stock max speed. The batteries in it have shown signs of sulphation, ie bulging ends, ever since I had bought the 2012 RXV they were installed in. I will be using one of my desulphating units on them to see if they can be improved. I'm sure the wreck I put them through did them no good

BobBoyce

Both of the seats on the 2008 had been under water for some period of time when the cart was flooded. The rear seat had broken in half underneath, and only the seat cover was holding it together. I unbolted and removed the rear seat a few days ago, and the "wood" seat bottom was mush, and totally falling apart. I had ordered a pair of new stock color seat cushions from uptopar a month ago. They finally arrived 2 days ago, so I went to work.

The front seat bottom is in bad shape as well. Not as bad as the rear seat, but I wanted to use the foam cushion from the rear seat to make a replacement seat, and to use that to replace the front seat first.

I needed a decent template, so I took the factory 2012 RXV seat apart and used the bottom of that as a template. I cut a couple of new seat bottoms out of pressure treated marine grade plywood and I painted them black. I bought all new T-Nuts, the originals were severely corroded and rusted.

I reused the cushion from the ruined 2008 seat, and I put a new seat cover on. I installed that seat in the front yesterday. The seat looks new, but is a lot harder on the rear to sit on. The seat cover is narrower at the top than the original, so the geometry is a bit different. Much better than the old seats however.

Here are some photos...

The old rear seat bottom. The 2012 seat bottom used as a template. The new marine grade plywood seat bottom. The new front seat bottom. And the new front seat top.

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	2012 Seat Bottom.jpg (28.9 KB, 0 views)
	New Seat Bottom.jpg (27.0 KB, 0 views)
	New Front Seat Bottom.jpg (111.3 KB, 0 views)
	New Front Seat Top.jpg (69.1 KB, 0 views)

Sir Nuke

Congrats!!