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Old 09-13-2011, 01:18 AM   #1
mkcop2002
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Default Building my first lifted Club car

OK fella's, I will warn ya now, I tend to get long winded and I apologize up front for that. Here goes, picked up my first cart a couple weeks ago, didn't know anything about 'em until then. My search was short as this was more of a spontaneous purchase/project. Being retired at a young age, not by choice, and being a very active person, my wife and I knew I would need a project, well, I found it. The Club car is an 1998 4 cycle and it was trade in I found sitting in the back of a local cart guy's lot. This cart was the second one I ever looked under the hood on, so I didnt know much, but my decision was between the club car and an EZ Go. I picked this one because of the aluminum frame and I knew I wanted to lift it, if in fact I decided to buy it. That and I knew my Buddy wanted the EZ Go. The owner could not tell me anything about the CC except it was a trade in. I looked it over as best I could and was hesitant because I had no idea if it even ran, but I liked what I seen, which was potential, but man, this thing was ugly.
My Buddy and I did ended up buying a couple carts, he bought the EZ Go and I got the Club Car. Once we got 'em home, which was a total trip in itself, because we found ourselves grinning from ear to ear like a couple of big kids and talking all kinds of cart talk and at one point, we ended up driving in the other lane due to some excitement about some "cart dreams".
So, within a couple hours we had them both running, and man, that was the start of something I hope I dont regret. Every night since I have been scouring the internet for parts, info. mods, you name it. My days were spent removing parts here and there, thinking where is the end to all these rusty parts. I regret now that I did not take any pictures of day #1, but I was trying to hide some of the ugliness b4 I brought it home since my wife has a hard time seeing the potential in things like this.
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Old 09-13-2011, 02:01 AM   #2
mkcop2002
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Default Re: Building my first lifted Club car

So, after a couple of days working on it a couple hours here and there, I finally got it stripped down. I found that I will need to the following parts, there is no rod connecting the gas pedal to the "black box". There is a bunch of nuts and bolts I will need which will be an easy find at the local hardware store. A new muffler (ouch $180 and up for new), a new drum because my dumba** broke one, a new black box and cover, a couple cables- fwd and rev cable for certain, but I will try and salvage the brake cables, will most likely need a new accel. cable. a new steering joint, probably some new bearings on the front hubs, seat covers, back rests, and a new steering wheel, just to get started for a few pieces. And of course, some rims, tires and a lift kit and a fresh coat of paint. All of this and I am new to welding and I dont know much about painting, but I am gonna learn, planning on a firemist metallic orange...shold look cool, if/when I get it that far. Sheeewwwwlllll.

OK, so parts are laying everywhere and Im seeing dollar signs, but trying to stay positive.
And I guess I could have just replaced a couple of things and got it running enough to just ride around, but I figured I may as well do a complete rebuild.

To catch up to where I am now...I started on the frame using a wire wheel, there was just all kinds of nastiness on it and it needed to go. It was a little more harsh than what I wanted to do, but my experience and resources was limited at this point. Most of the frame is done, but not all and that brought me up to yesterday, 9-11. I got tired and needed a break, so I started taking the shrouds off of the engine which revealed even more dirt, grease and grime. I made a few trips to the garage only to get discouraged each time at all the mess on that engine. I have sprayed it with degreaser, then more degreaser, then brake cleaner, WD40, and I used a putty knife for the heavy stuff, trying to make sure I left no scratches. But sheesh, I was not getting anywhere. Last night (I am a night owl) I finally settled in with a better attitude and a small brush and some hand cleaner. That helped cut through the gunk, but it was taking forever. I got a lot of stuff off the engine and if I had nothing else, that would be the easiest thing I have found so far.
I came inside and sat down and started looking around for a solution when I stumbled onto baking soda blasting. That lit a new fire and I was ready to go shopping.
I have been in need a new air compressor for many years as the one I have it old and way too small. Originally I thought I would make my own soda blaster (as seen on you tube) but while I was at Tractor Supply I found a blasting gun kit for $20. I tell ya, I never realized how much time it would take to get a new compressor and get it up and running. This is one part that someone else may appreciate and may use to help them out. I needed to finish cleaning my frame, rear end and the engine. I have parts on order and will pulling the trigger on a lift kit, rims and tires, tonight or tomorrow. When I get those parts, I dont want to be cleaning, I want to be building. Now, one guy suggested I take the alum. frame to a truck stop and have it cleaned. I wish I would have known that before I wheeled on it, as that sounds like a perfect suggestion. Anyways, I decided soda blasting would be my key to cleaning rust and the frame and getting it done a little faster. So, I went to Harbor freight and bought 2 bags of the soda blasting stuff, one medium and one heavy, I also picked up some saftey equipment too, new goggles, a shield, etc. Then, to tractor supply for a new compressor and I found that gun kit. I also bought some new fittings and new airline and then made a trip to home depot for an electric cord for the compressor. I already had 220 in the garage, but I did not want to hard wire the compressor. Anyways, several hours later I am home putting on fittings, filters, wires, you name it. One more trip back to homedepot b4 I am done and by 9:30 I was finally spraying soda out of the nozzle looking for a miracle. I am pleased with the results, but it is no miracle. Basically, anyone need to clean grease and grime would probably benefit from soda blasting, but it makes a white cloud of a mess and looks like a cocaine party that went bad when your finished. Since American Chopper was on, I knew I had to cut the evening short. So I placed a bunch of the rusty nuts and bolts in a container with white vinegar and went in for the night. I will post some pictures of the project, but there isnt much to look at right now. My shop, as large as it is, seems to get messy easy, so please overlook that.
My plans tomorrow will be to continue blasting away the rust and cleaning that frame while I wait on new parts. I hope to have it in rolling chasis by the end of the weekend. I still need to order a new steering wheel (I hate the stock one), seat covers, and bushings. I havent decided what I am going to do for the floor mat, but I am leaning towards a black rubber diamond thread. I will need to fab some back rests and once t he body is on I do plan to bend out some sort of front bumper and add some lights. I did get a decent deal on a new muffler on ebay, like 89 bucks I think it was. I also ordered some diamond plate trim pieces for each side. My Buddy donated a piece of stainless tube that fits perfectly over the steering column, so thats cool. I also have to decide on a top. I may just go with a sport type windshield?
I am considering strongly, a 6" super sport lift with the STI B6 12" rims and AT tires. I plan to do some light trails, and may eventually put a snow plow on. Ok, So any thoughts so far??
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Old 09-13-2011, 02:14 AM   #3
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Default Re: Building my first lifted Club car

Told ya I was long winded....Sorry...
OK...so...I am a little worried about the lift kit. One thing for sure, I hate the stock ride on the EZ go, never rode on a Club car. The EZ Go just jars the heck out of me and I want something a little softer, plus the wife wouldnt like it either.
I really like the long travel lift kit, but the price scared me away and I wont be doing any harsh trail riding. My thoughts are that by going with the 6" lift I should get a better ride, some of which will come from the tires, I assume? Those little stubby shocks arent much, which is why I was attracted to the long travel lift with those awesome looking shocks, but $$$? And, after looking around here I see that some people have went to monroe shocks, so I will probably do the same and hope that gives me a decent ride. Ok, I have typed out so much here, I think I will break it down in list form as to what I have ordered, and then what my plans are, even colors so that someone can throw their .02 cents in there in case it is gonna be ugly or not work well. I will also need to play around with the engine as I want to get 20 to 25 mph, if possible, on the stock engine.

Parts ordered:
Accelerator rod
Steering joint
rear brake drum
black box
cover for box
F&R cable
bellows(steering box-both sides)
new micro switch
Diamond plate side trim inserts
Have: Stainless colummn cover
Diamond plate side trim pieces
Tune up kit

Will order:6" super sport lift
Tires and rims
new bushings for the leaf sprinigs ( I wonder if I can find some at the local auto store?)
new ground wires
shocks
I also need to find an inner fender somwhere???

Maybe???
I might need new hub bearings
Brakes?
Brake cables??? Not sure yet.
CF Dash
CF steering wheel

For finish I am looking at a metallic firemist orange for the body, it is single stage paint, which I think should be a good way to start myself out painting. I have a decent spray gun and now, a good compressor.
Seat covers, I am looking at a black w/ carbon color strips on the ends, a CF simulated dash panel and matching steering wheel.
Black diamond plate rubber mat for the floor.
Light kit.
I plan to use that black bumper paint for the black fender cover pieces and the rear hatch cover, and the current dash if I change my mind on the dash kit.
All of the metal brackets will be painted flat black, although for some reason I thought about painting the engine tray red, I dont know why.
I'd also like to do something with the brake and gas pedals, any ideas here?
I may end up putting on some fender flares, but I will see where I am at cost wise.

I am begining to wonder if I am putting too much into this cart. All said and done, I hope to be under 2,000, I gave 700 for the cart, so I dont know. OK, does it sound like I am on the right track here?
I have always been a 4 wheeler or dirt bike kind of person, but my wife and I arent getting any younger and we both have some health issues, so we need to settle down a bit. I think some easy cruising will do us good, and occasional trail or two.
And is my expectations decent in thinking I may be able to hit 20+ mph on this thing? More would be better, at least for on road use.
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Old 09-13-2011, 02:20 AM   #4
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Default Re: Building my first lifted Club car

Here are the pieces, I mean pics...
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Old 09-13-2011, 11:32 AM   #5
WW
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Default Re: Building my first lifted Club car

Honda XR50 coil over shocks will fit the front. Just need 3 steel and 1 stainless steel washer to fill the gap on the bottom.
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Old 09-13-2011, 09:53 PM   #6
mkcop2002
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Default Re: Building my first lifted Club car

Thanks WW, great info, once again. It's kind of funny, Ive been thinking all day about shocks, mostly because I said I was going to order a lift kit package today. Well, I didnt do it, I decided to hold off because I may need some more things and one order is better than six...ha! Which may mean my rolling chasis goal is not feasible.
Well, I managed to get quite a few of the metal brackets de-rusted and shot a coat of rustoleum on 'em. Im using that rattle can stuff, that says it stops rust, blah blah blah. I dont know if it works, Ive used on touch up for my Jeep frames, but that was failry recent, so no time proven experience here. I plan to work on the leaf springs tomorrow and get them in paint as well as the axle. Found out today that I will also need new brake shoes, but I have salvaged the brake cables. I may be ready to place that order now.
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Old 09-15-2011, 03:15 AM   #7
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Default Re: Building my first lifted Club car

I will have to take some pics tomorrow or friday, working on putting that engine back together, most painting is done aside from the body. All parts ordered, except for seat covers, steering wheel and a couple other things I am putting off until I know for certain what color I am going with. Pics coming as it is almost looking hopeful again.
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Old 09-15-2011, 07:56 AM   #8
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Default Re: Building my first lifted Club car

Cool project! We need more pics!!

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Old 09-16-2011, 02:41 AM   #9
mkcop2002
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Default Re: Building my first lifted Club car

Well, still working on pics, sorry. Bad night, ran out of gas, 'cause, well, I have no excuse, except i was trying to make it to the auto store b4 they closed, driving right by the gas station, smart move huh.
We ended up walking home 'cause I dont like to ask anyone for help, to top it off, it rained,, at least it was only a mile and half home.
Need a new battery in the Jeep too! So, soak and wet and a very late dinner, but then a little work did get done. Then today, had to put new brakes on the wife's Jeep. I did however, manage to squeeze some more work in today b4 i got interrupted.
The engine is looking good, just waiting on new carb gaskets and it will be back in one piece. Got most of the painting done on the brackets, (keep finding more stuff to paint, just when I think I am done) almost ready to install the lift kit once it gets here, maybe friday...hopefully. And darn it if I dont still need to order some more parts...for the life of me, why cant I just have access to a golf cart junk yard. Ha. I need an inner fender if anyone has one to sell. And, once the chasis is back to a functional piece of work, I guess I will start painting the body.
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Old 09-17-2011, 10:24 PM   #10
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Default Re: Building my first lifted Club car

I got some packages today, my lift kit and tires/rims. Off to the shop to see what I can get done. I managed to get most of the front end installed and I had to go ahead and mount the rims to see how it looks. I am amazed at how high the cart sits now, this is going to turn out pretty nice, I think. The front end is not complete, I will have to pack grease into the hubs and I may replace a bearing on the pass side. I also need to find a hub cover and a washer which was missing.
I'm using the All Sport Super sport 6" lift and I tell ya, it bolts right on and is super simple to install. The only flaw I found so far is that they sent me a shorter bolt than what I need, no big deal, a trip to the hardware store will fix that, however, spending that much money, it would have been nice to have had the right stuff.
I am including some pics and you will be able to see the engine. I cleaned it as best as I was capable of here at home and it is good enough for me, although I would have preferred it to be like new, but it is what, 13 years old, so not bad huh. Still waiting on more parts and a couple more parts to order, but I did manage to start on some body work. Dead line is October 1st, I hope I make it with time to spare so I can make sure it is trail worthy.
Im starting the thought process on a top now, I have some ideas, but I have not settled on anything. Im not super excited about the factory top so I may try and fab something, although I am slightly lacking on some tools. Also not completely settled on a paint color and so I am holding off on ordering seat covers, but I need to make a decision here soon.
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