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Unread 07-07-2019, 12:41 PM   #1
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Default My 98 DS resurrection

Starting the work this week. More to follow in the coming weeks :)

I picked up a 1998 DS for pretty cheap. I messed with it a little, jumped the solenoid (the wiring is completely jacked up, will have to be redone. Too many rednecks in this thing...) and I did get it to run. Destruction ensued. It ran, fairly well actually. But man oh man the noises it made! And the mess on the ground.

So, out comes the engine. Leta find what's making all that noise. I didnt have to take apart the motor to see it. Conveniently there was a nice window in the back of the block where the counterweight *used* to go. No more guesswork here, the motor isnt rebuildable! Not without JB weld and I plan to sell this once its finished and run around a bit, so I'm not gonna go that route

A couple pictures to start with, how I brought it home and some fun motor carnage. The governor was disconnected, the pedal cable ran straight to the carb and the rev limiter is completely gone. So not much guessing what went wrong.

Of course, the guy said it just needs a solenoid and carb cleaned. Not that I believed him, but also he wasnt completely wrong
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Unread 07-07-2019, 12:52 PM   #2
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Default Re: My 98 DS resurrection

First update, I found a Facebook find... complete top and seat backs for $100 in excellent shape. It came with a top and the rear struts, but the top is pretty rough and it had no front support. Those are next to impossible to find! I'll still need a seat bottom but those arent that expensive on ebay. The bottom wood is gone, cover is gone, it's basically foam with a couple 1x8's and the hip restraints

Since the motor that came with it was unusable, I got a "rough" FE350 from a member here. I took it apart and will be ordering parts to rebuild it tomorrow. The cylinder has no cross hatching left, but its round and no scoring at all. He said it ran but smoked, and I can see that it smoked for a very long time judging by the amount of carbon build up in the exhaust port of the head . Both valves are junk, but rod is in spec, crank and cam look/measure great, so I've got a game plan

Tonight I will be pulling the body for some deep cleaning, wiring, and paint. The body itself is actually in good shape, despite the spraypaint. I'll work on all that while waiting for motor parts to arrive :)
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Unread 07-07-2019, 12:55 PM   #3
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Default Re: My 98 DS resurrection

Got a little cleaned on the head. Still need to take the dremel with a little wire wheel to it, but chipped most of the carbon out of it. Motor should be able the breathe now
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Unread 07-09-2019, 05:39 PM   #4
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Default Re: My 98 DS resurrection

Last night I got the body pulled off and everything taken apart. What a mess. This afternoon I cleaned the frame and got all the mud off, it's much lighter now!

Stripped all the spray paint off the body too. Got a couple small scratches to fix but nothing too major. Hope to get the body sanded and prepped tonight, maybe even a first coat of primer.

Changing direction with the engine, made a little road trip yesterday and picked up bluedubpirate's fe350 he removed for a vanguard. Hope to get that installed tonight as well. New microswitches will arrive tomorrow and the rewiring will begin.

As a side note, he took me for a little ride in his vanguard carryall. Thing is a beast! And what a nice ride, the pictures in his build thread really dont do it justice. He did a great job on that for sure, and I'll be giving his old motor a nice new home to play in :)
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Unread 07-10-2019, 05:31 AM   #5
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Default Re: My 98 DS resurrection

Sounds like my cart when I got it, pretty sure I removed over 20 lbs of dirt from mine.

Little sad to see that sweet paint job go away!

So what's the overall plan for this build? What mods are you going with?
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Unread 07-10-2019, 07:39 AM   #6
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Default Re: My 98 DS resurrection

Is that a chunk of wood for a snubber? Custom.
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Unread 07-10-2019, 08:57 AM   #7
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Default Re: My 98 DS resurrection

yep! Actually it's a custom 4 layer snubber. 1 layer of some type of almost completely disintegrated foam, and 3 layers of what appears to be firewood chunks glued together. Undetermined if they're held together with glue or engine oil/sludge

Basic plans for the build are tossing out the old FE290 (done). Install FE350 (done last night). Unplugged the kill wire and jumped the solenoid, seems to run pretty good. Have all new microswitches arriving today so I'll rewire everything and finish gutting the rest of the lamp cord out of the cart and rewiring everything correctly. Then it should start up and run like it's supposed to! I've already removed about 30 ft of lamp cord. I don't know how the PO is able to see in his house after he must have sacrificed every lamp he owns

Then need to clean up, fix the holes in the front cowl from the big ugly fog lights the PO installed, paint the body. Picked up all my paint supplies yesterday, going with a "deep blue metallic" paint Suspension is COMPLETELY shot, every bushing in the cart is non-existent so I'll get new leaf spring bushings for the rear and add a 6" lift to replace all the worn out front components. 10 or 12" wheels with 23-25" tires are in the plans. new steering rack or u-joints in the coupler, steering wheel is pretty notchy and haven't looked at it much to see what's wrong. Probably end up doing both so everything is new and don't have to worry about it.

With some new microswitches and wiring repairs, it will run/drive like it's supposed to. After that is the fun part where it's all down hill and the real transformation begins. That's the part I like best. It's already come a long ways since I drug it out of the bushes in the guys yard. :)
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Unread 07-10-2019, 09:12 AM   #8
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Default Re: My 98 DS resurrection

Should be a great cart when you get done. I had a similar experience with my 96 DS after I decided to big block it. Didn't like the suspension or wheels, so a 4" lift and SS 12" wheels with 22" tires went on. Had to swap to high speed gears to take full advantage of the BB. Hated the steering, so ordered a new rack along with all new tie rod ends. Now I'm working on painting the body to get away from the factory cream color and ordered new seats to match.

Basically, it will be a brand new 21 year old cart when you're done!
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Unread 07-10-2019, 09:17 AM   #9
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Default Re: My 98 DS resurrection

That's basically the same case with my carryall, you can see it in the background of a couple of the pictures. I don't think there's anything in that cart aside from the frame and rear end that hasn't been rebuilt or replaced. That thing is a tank! And with the lift and 25" tires, I don't bottom out as I drive down my driveway anymore :)
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Unread 07-11-2019, 12:20 AM   #10
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Default Re: My 98 DS resurrection

Quick update. All the wiring has been fixed. I need to replace the fuse holder because the main fuse terminal is broken, but that's no problem. I have lots of fuse holders


3 of 4 microswitches were bad. Solenoid was bad, it clicked but no continuity between the 2 large lugs. Repaired the wiring at the rev limiter. Need a new key switch but the wiring behind it has been corrected. I'd just prefer to use a key and not a pocket knife

Hooked up a temp fuel tank (need to clean the original... its beyond nasty) and I will probably drop the carb in the ultrasonic cleaner just to ensure theres no issues there.

Now it starts and runs like it should. Steering rack is fine, the u joints are bad. Easy fix. Mechanically and operationally it's almost there. Should be drivable by this weekend. Then its just suspension, aesthetics, and toys and as a bonus, the manufacture date stamped on the motor is 10/2013 so it must have been replaced in his cart before he got it. :)

https://www.youtube.com/watch?v=juWsLk5BrIM
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