Having serious doubts

bradbates · 11-13-2017, 09:24 AM

I'm beginning to think we bought a POS. 1987 Club Car DS. I can deal with shoddy work and wiring done by previous owner/owners but....every time I turn around it seems another issue arises. Previous owner had a spring on the carb that should not have been causing the cart to run erratically, got that figured out. Wiring was a disaster including 110v lamp cord used, got that fixed. Low oil light inoperative and NO wire running from the engine to the dash, got that fixed. It has a flip seat. Ordered and installing heavier springs but NO, gotta have longer u-bolts which didn't dawn on me and I'm waiting on those to arrive. Front end is worn out and I can deal with that, understandable on a 30 year old machine. I have the cart on jack stands in the rear for the spring job and we've been getting a STRONG gasoline odor in the garage. It appears the plastic gas tank has either a crack or soft spot bottom front. It's one thing after another. I can't seem to locate a gas tank and if I did the rear body has to come off to change it out which means the flip seat hardware all has to come off as well. I wish we'd spent another grand and bought something newer! Body is in great shape, I have a new roof waiting to install, seats are very good shape. I don't know, somebody talk me out of setting this thing on fire.

Springbok · 11-13-2017, 10:45 AM

If it runs it's not junk! Post some pictures of it for us. From reading your post your main beefs are having to wait for longer leaf springs (sounds like you got that figured out), but your main issue now is that gas tank. I'd take the body off and find out what the issue is. If it's just a pinhole you may be able to plastic-weld it. If not, and you can't find a good used one, the 1992-up gas tank (which can be purchased new) will fit just fine.

I just built a '90 gas Club Car and had some annoying issues, including a bad gas tank! It was left exposed to the sun for too long (2 years) and when I leaned on it, my hand broke the top corner off...lol. Both carts I own were acquired with more or less blown motors. If yours runs you're miles ahead of me...unless you paid too much for yours.

My builds (both carts basically the same as yours):

1987 CC gas
http://www.buggiesgonewild.com/membe...-club-car.html

1990 CC gas
http://www.buggiesgonewild.com/membe...-club-car.html

Springbok · 11-13-2017, 10:52 AM

Here's another thread where we went over gas tanks in the old DS carts. One of our members confirmed that he was able to install a 1992+ DS gas tank in his '86 DS. So if you need a new tank it sounds like you can just find a used one from any gas CC DS cart from 1984-up; or just get a brand new one, which are available online.

http://www.buggiesgonewild.com/gas-c...-gas-tank.html

bradbates · 11-13-2017, 10:53 AM

Leaf springs are in and they fit, it's the longer u-bolts necessary to attach the thicker heavy duty springs that I hadn't taken into consideration. So? You say a tank for a 1992 will fit my 1987? I find tanks and they have the serial numbers listed of carts that they fit but, my serial number is not listed and I am told by a fella at Matt at golfpartsdirect.com those tanks have been discontinued.

Springbok · 11-13-2017, 10:59 AM

Yes the newer tanks will fit. Frame rails were never changed in any meaningful way on these carts over the years, and we have a member here who confirmed that he put a 1992+ tank in his '86. Yes I believe all of the fuel tank designs built prior to 1991 have been discontinued. If you want the exact tank for your model year, gotta find one used.

bradbates · 11-13-2017, 11:06 AM

If I'm going to remove the rear body I'd just as soon put a new one in if it'll fit without a bunch of fab work. One thing I've never been able to determine is if the original '87 gas tank is vented or not. When I got the cart, right off the bat I had to replace the fuel cap because the gasket inside was shot and gas was sloshing out the fill.

Springbok · 11-13-2017, 11:17 AM

If you check out that thread I posted, all the guy said was that it fit right in and all he had to do was re-mount his fuel pump. These gas tanks are only held down against the frame with adjustable hoop straps that run over the top of the tank, there's no complicated bracket system to worry about. So I doubt that having to fab stuff up would be concern. You should be fine.

And the rear body comes off easy enough (once your rear seat is removed): Two bolts in the bag well, six bolts at the seat back supports, two bolts down near the back of the floor mat. Then just unbolt your shifter assembly and pull it off.

And I'm pretty sure the gas tanks in both my '87 and my '90 are non-vented.

bradbates · 11-13-2017, 11:41 AM

Just to confirm because.....I should get the tank listed 1992-1996 and it will drop right in my 1987? How exactly does one mount the fuel pump? Mine is mounted to the side of the tank.

Springbok · 11-13-2017, 12:45 PM

Like I said, according to a member here (Wallbanger), he said that the 1992+ tank dropped right into his '86 and all he had to do was re-mount his fuel pump. I personally have no experience mounting the newer tank in the older carts, but I find it very plausible and easy to believe that it can be done with little trouble, and one of our members has confirmed that he did it. That's enough for me. If you want further info, I'd try and message Wallbanger. But yes, if I were ordering a new tank for myself, I'd try and order the closest available tank to my model year, which would be the 1992-1996 tank.

As far as the fuel pump mounting, on the newer carts the pump is mounted on either the metal body support bracket, or on the front gas tank strap. I'd just try to mount it at the same height.

I know what you mean, the pump on my '87 is bolted right to the tank as well (red box). On my '90 it bolts to the strap (blue box).

Here's the breakdown of the tanks. You can see that the 1992-1996 tank style was actually introduced during the latter run of 1991 models (green box):

bradbates · 11-13-2017, 03:56 PM

Thank you sir. I'll message him if he's still on here and ask what he did to mount the fuel pump.

It looks like the blue, green and purple border pics have a fuel pump mount attached to the strap. Maybe I need one of those.

11-13-2017, 09:24 AM	#1
bradbates Not Yet Wild Join Date: Oct 2017 Location: Carthage, MO Posts: 18	Having serious doubts I'm beginning to think we bought a POS. 1987 Club Car DS. I can deal with shoddy work and wiring done by previous owner/owners but....every time I turn around it seems another issue arises. Previous owner had a spring on the carb that should not have been causing the cart to run erratically, got that figured out. Wiring was a disaster including 110v lamp cord used, got that fixed. Low oil light inoperative and NO wire running from the engine to the dash, got that fixed. It has a flip seat. Ordered and installing heavier springs but NO, gotta have longer u-bolts which didn't dawn on me and I'm waiting on those to arrive. Front end is worn out and I can deal with that, understandable on a 30 year old machine. I have the cart on jack stands in the rear for the spring job and we've been getting a STRONG gasoline odor in the garage. It appears the plastic gas tank has either a crack or soft spot bottom front. It's one thing after another. I can't seem to locate a gas tank and if I did the rear body has to come off to change it out which means the flip seat hardware all has to come off as well. I wish we'd spent another grand and bought something newer! Body is in great shape, I have a new roof waiting to install, seats are very good shape. I don't know, somebody talk me out of setting this thing on fire.

11-13-2017, 10:45 AM	#2
Springbok Photoshop Guy Join Date: Aug 2012 Location: Canal Fulton, OH Posts: 3,846	Re: Having serious doubts If it runs it's not junk! Post some pictures of it for us. From reading your post your main beefs are having to wait for longer leaf springs (sounds like you got that figured out), but your main issue now is that gas tank. I'd take the body off and find out what the issue is. If it's just a pinhole you may be able to plastic-weld it. If not, and you can't find a good used one, the 1992-up gas tank (which can be purchased new) will fit just fine. I just built a '90 gas Club Car and had some annoying issues, including a bad gas tank! It was left exposed to the sun for too long (2 years) and when I leaned on it, my hand broke the top corner off...lol. Both carts I own were acquired with more or less blown motors. If yours runs you're miles ahead of me...unless you paid too much for yours. My builds (both carts basically the same as yours): 1987 CC gas http://www.buggiesgonewild.com/membe...-club-car.html 1990 CC gas http://www.buggiesgonewild.com/membe...-club-car.html

11-13-2017, 10:52 AM	#3
Springbok Photoshop Guy Join Date: Aug 2012 Location: Canal Fulton, OH Posts: 3,846	Re: Having serious doubts Here's another thread where we went over gas tanks in the old DS carts. One of our members confirmed that he was able to install a 1992+ DS gas tank in his '86 DS. So if you need a new tank it sounds like you can just find a used one from any gas CC DS cart from 1984-up; or just get a brand new one, which are available online. http://www.buggiesgonewild.com/gas-c...-gas-tank.html

11-13-2017, 10:53 AM	#4
bradbates Not Yet Wild Join Date: Oct 2017 Location: Carthage, MO Posts: 18	Re: Having serious doubts Leaf springs are in and they fit, it's the longer u-bolts necessary to attach the thicker heavy duty springs that I hadn't taken into consideration. So? You say a tank for a 1992 will fit my 1987? I find tanks and they have the serial numbers listed of carts that they fit but, my serial number is not listed and I am told by a fella at Matt at golfpartsdirect.com those tanks have been discontinued.

11-13-2017, 10:59 AM	#5
Springbok Photoshop Guy Join Date: Aug 2012 Location: Canal Fulton, OH Posts: 3,846	Re: Having serious doubts Yes the newer tanks will fit. Frame rails were never changed in any meaningful way on these carts over the years, and we have a member here who confirmed that he put a 1992+ tank in his '86. Yes I believe all of the fuel tank designs built prior to 1991 have been discontinued. If you want the exact tank for your model year, gotta find one used.

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11-13-2017, 11:06 AM	#6
bradbates Not Yet Wild Join Date: Oct 2017 Location: Carthage, MO Posts: 18	Re: Having serious doubts If I'm going to remove the rear body I'd just as soon put a new one in if it'll fit without a bunch of fab work. One thing I've never been able to determine is if the original '87 gas tank is vented or not. When I got the cart, right off the bat I had to replace the fuel cap because the gasket inside was shot and gas was sloshing out the fill.

11-13-2017, 11:17 AM	#7
Springbok Photoshop Guy Join Date: Aug 2012 Location: Canal Fulton, OH Posts: 3,846	Re: Having serious doubts If you check out that thread I posted, all the guy said was that it fit right in and all he had to do was re-mount his fuel pump. These gas tanks are only held down against the frame with adjustable hoop straps that run over the top of the tank, there's no complicated bracket system to worry about. So I doubt that having to fab stuff up would be concern. You should be fine. And the rear body comes off easy enough (once your rear seat is removed): Two bolts in the bag well, six bolts at the seat back supports, two bolts down near the back of the floor mat. Then just unbolt your shifter assembly and pull it off. And I'm pretty sure the gas tanks in both my '87 and my '90 are non-vented.

11-13-2017, 11:41 AM	#8
bradbates Not Yet Wild Join Date: Oct 2017 Location: Carthage, MO Posts: 18	Re: Having serious doubts Just to confirm because.....I should get the tank listed 1992-1996 and it will drop right in my 1987? How exactly does one mount the fuel pump? Mine is mounted to the side of the tank.

11-13-2017, 12:45 PM	#9
Springbok Photoshop Guy Join Date: Aug 2012 Location: Canal Fulton, OH Posts: 3,846	Re: Having serious doubts Like I said, according to a member here (Wallbanger), he said that the 1992+ tank dropped right into his '86 and all he had to do was re-mount his fuel pump. I personally have no experience mounting the newer tank in the older carts, but I find it very plausible and easy to believe that it can be done with little trouble, and one of our members has confirmed that he did it. That's enough for me. If you want further info, I'd try and message Wallbanger. But yes, if I were ordering a new tank for myself, I'd try and order the closest available tank to my model year, which would be the 1992-1996 tank. As far as the fuel pump mounting, on the newer carts the pump is mounted on either the metal body support bracket, or on the front gas tank strap. I'd just try to mount it at the same height. I know what you mean, the pump on my '87 is bolted right to the tank as well (red box). On my '90 it bolts to the strap (blue box). Here's the breakdown of the tanks. You can see that the 1992-1996 tank style was actually introduced during the latter run of 1991 models (green box):

11-13-2017, 03:56 PM	#10
bradbates Not Yet Wild Join Date: Oct 2017 Location: Carthage, MO Posts: 18	Re: Having serious doubts Thank you sir. I'll message him if he's still on here and ask what he did to mount the fuel pump. It looks like the blue, green and purple border pics have a fuel pump mount attached to the strap. Maybe I need one of those.