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Unread 10-18-2018, 09:46 AM   #1
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Default 92 CC DS gas, convert to lithium electric rebuild thread

I enjoy seeing others build threads, so I decided to start my own. As some of you know, I have already started this build a couple months ago, so it will take a little bit before I get this thread to current status of the build.


I decided to do a hunting buggy. The family of a buddy of mine owns a campground, so I asked if they had any golf cars that were "put out to pasture". They had 3. An 80's Hyundai, with a cracked frame. An 81' CC DS, was in rough shape! And this 92' CC DS gas. The engine was toast, they didn't feel like dealing with it, so I got it for free. My friend was apparently over excited and loaded it into his Ranger, and drove it to my house. The Ranger was definitely struggling!

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Unread 10-18-2018, 09:51 AM   #2
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Default Re: 92 CC DS gas, convert to lithium electric rebuild thread

I like your 2nd and 3rd choice pics as a project, but trust me friend, give up on the 1st one, its a waste of money....

All jokes aside (except the FoMoCo one ), it is going to be great when done.
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Unread 10-18-2018, 12:03 PM   #3
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Default Re: 92 CC DS gas, convert to lithium electric rebuild thread

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The pictures do not do justice to the amount of grease, oil, dirt and whatever the heck else was caked all over everything!


I thought I hated stickers before this. Now I refer to it as the devil's candy, along with chewing gum! Why do people feel the need to put stickers all over everything!?!?!?


A little bit of fiber glass damage.
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Unread 10-18-2018, 12:43 PM   #4
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Default Re: 92 CC DS gas, convert to lithium electric rebuild thread

BBBHC good luck with the project! What are you going to use for a rear?

Don't throw those parts away! They are getting hard to find and some people would love to have them.
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Unread 10-18-2018, 01:06 PM   #5
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Default Re: 92 CC DS gas, convert to lithium electric rebuild thread

I’m gonna have to keep an eye on this. Been considering doing the same thing. I have a 91 that the trans is pretty much shot in, looks like the rear axle is the same as electric axles but haven’t pulled it apart yet to really see. If it is I’ve got full harness and electronics from a 98 I scrapped two years ago, would be a neat project for this winter. The only expensive part would be batteries.
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Unread 10-18-2018, 03:31 PM   #6
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Default Re: 92 CC DS gas, convert to lithium electric rebuild thread

Quote:
Originally Posted by Mooncarter View Post
BBBHC good luck with the project! What are you going to use for a rear?

Don't throw those parts away! They are getting hard to find and some people would love to have them.
Thanks Mooncarter!
I ended up getting a new rear end from Davidhttp://www.revolutiongolfcars.com/ . It was out of a 2013 or 14' CC P electric, not sure which now, he had 5 of them at the time. Perfect swap.


The parts I don't end up using are going back to my buddy, certainly won't be wasted!
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Unread 10-18-2018, 03:40 PM   #7
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Default Re: 92 CC DS gas, convert to lithium electric rebuild thread

Quote:
Originally Posted by Fairtax4me View Post
Iím gonna have to keep an eye on this. Been considering doing the same thing. I have a 91 that the trans is pretty much shot in, looks like the rear axle is the same as electric axles but havenít pulled it apart yet to really see. If it is Iíve got full harness and electronics from a 98 I scrapped two years ago, would be a neat project for this winter. The only expensive part would be batteries.
I can not speak to 91'. However, for the 92, I am told it is a Kawasaki drive unit, the motor will bolt right up to it. However, the gearing is not right for the application. It was somewhere close to 6.25:1. The normal gearing for electric CC's is somewhere close to 12.25:1.

I would imagine the 91' would be the same scenario, but do not know for sure.
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Unread 10-18-2018, 03:59 PM   #8
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Default Re: 92 CC DS gas, convert to lithium electric rebuild thread

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Disassembly begins! Once I removed enough of the 1/4" plus of caked on whatever the heck, I was able to remove all the components. Pretty sure no one did any kind cleaning to this thing for at least 5 years!

That insulation/isolation they put between the engine cradle and the engine, holds a lot of really disgusting liquid!
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Unread 10-18-2018, 07:23 PM   #9
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Default Re: 92 CC DS gas, convert to lithium electric rebuild thread

After lots of Goo-Gone, razors, Scrubs in a bucket hand cleaner towels, Simple Green and power washing.

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Unread 10-18-2018, 08:53 PM   #10
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Default Re: 92 CC DS gas, convert to lithium electric rebuild thread

Frame looks way better after all that work! You could use an acid wash on it and get the rest of the oxidation off of there and really brighten it up.
Quote:
gearing is not right for the application. It was somewhere close to 6.25:1. The normal gearing for electric CC's is somewhere close to 12.25:1.
Thanks, I had wondered if that was different. I’ll have to check that. I do have a spare axle from another cart but it needs bearings. It would be a speed demon for sure! That’s not exactly the direction I would need to go with it though. With the hills here we need the torque.
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