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Unread 03-18-2017, 12:56 AM   #11
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Default Re: 1999 Club Car DS body cracked

It will take days, lots of work, and lots of money to fix that. Then you have to paint it. I would suggest, as other members have, replace the thing.
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Unread 03-18-2017, 07:37 PM   #12
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Default Re: 1999 Club Car DS body cracked

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Originally Posted by 55BigBlock View Post
The DS body is made of a material they call "Armorflex". It is a polycarbonate. There is no adhesive I've found that will fuse to this material. I've tried epoxies, cyanoacrylates (super glue), panel adhesives, and hot melt adhesives to no avail. Some seem to stick, but all succumbed to moderate pressure. The only thing you can do is use a soldering iron or some other type plastic welder and try to "stitch" it together from the back side. If you take your time and try to reinforce it with some donor material you might get by. I'd look at a new complete replacement body. They are very reasonable and the color is molded through.
Are the TXT's made of Armorflex as well?

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Unread 03-18-2017, 07:39 PM   #13
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Default Re: 1999 Club Car DS body cracked

Sorry, I should have said EZ Go TXT's.

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Unread 03-18-2017, 08:03 PM   #14
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Default Re: 1999 Club Car DS body cracked

Hey SGF. I think Armorflex is a proprietary material trademarked by Club Car. Is it significantly different from EZGO's material? I don't know.

Also Dannybear, if you have any doubt whether this material will crack or split, look at the first 2 photos in this thread. LOL. Not laughing at you, just laughing.
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Unread 03-18-2017, 08:15 PM   #15
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Default Re: 1999 Club Car DS body cracked

That front end is NOT polycarbonate
Everything I read says ABS, thats what the front of my XRT is made from and I have had a crack welded on it.
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Unread 03-18-2017, 10:03 PM   #16
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Default Re: 1999 Club Car DS body cracked

Ok Dannybear. I may stand corrected, I can assure you I don't know the science. However, polycarbonate, lexan, armorflex, abs, etc, I can also assure you any of these materials can and will crack.

Just trying to help this guy out with his DS front end without him spending a ton of time and money fixing something that ain't worth fixing. I have one here I will give him if he wants to come get it. Or, you can go over his place and "weld" the thing for him. LOL.
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Unread 03-18-2017, 10:13 PM   #17
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Default Re: 1999 Club Car DS body cracked

Ahhh, but I do know the science, sold plastics for 15 years, look at it like this , Polycarbonate is Lexan, it is bullet proof for most rifle rounds when its 3/4" thick, it does not crack like that front cowl.
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Unread 03-18-2017, 10:20 PM   #18
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Default Re: 1999 Club Car DS body cracked

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Originally Posted by DannyAbear View Post
Ahhh, but I do know the science, sold plastics for 15 years, look at it like this , Polycarbonate is Lexan, it is bullet proof for most rifle rounds when its 3/4" thick, it does not crack like that front cowl.
Lexan is a polycarbonate, so is a compact disc. They break all the time professor. Just build him one from 3/4 inch lexan and be done with it Einstein.
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Unread 03-18-2017, 10:36 PM   #19
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Default Re: 1999 Club Car DS body cracked

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Unread 03-18-2017, 10:39 PM   #20
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Default Re: 1999 Club Car DS body cracked

Me too. LOL.
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