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Old 01-29-2018, 09:48 PM   #1
cobolnofun
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Default My Winter* Project: a 1990 ds

I picked up a 1990 ds last June to drive around the neighborhood and head down to the pool. Not knowing much about golf carts i kinda skipped over the whole battery/wiring thing and just looked at the mechanical and thought "this will be a good winter project for me" It has a long roof and a back seat, 4 whole cup holders how could i go wrong?

About a month later i was buying new batteries . It made it to winter though.

Here is where i started. A few days after i got her i changed the diff fluid and got this picture. Diff fluid appeared to have never been changed. A common theme i am starting to notice.
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Old 01-29-2018, 09:53 PM   #2
cobolnofun
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Default Re: My Winter* Project: a 1990 ds

I decided to start with the front suspension so i could also survey the damage from what appears to be a heavy front collision at some point in its life.

After getting the front cowl off... this is officially the oldest thing i have worked on. The previous winner was a 91 corsica. I am waiting on the rear suspension parts... so you are going to get batches of posts if you follow this thread
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Old 01-29-2018, 09:58 PM   #3
cobolnofun
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Default Re: My Winter* Project: a 1990 ds

I took everything off the front end and cleaned up the parts to find out what exactly needed to be replaced.

picture 1 is fresh off the cart
picture 2 is after a soak in degreaser
picture 3 is the rinse after soaking in engine cleaner
picture 4 is the final state of the parts
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Old 01-29-2018, 10:06 PM   #4
cobolnofun
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Default Re: My Winter* Project: a 1990 ds

make shift paint booth for the parts that were still usable but kinda gross

and where i netted out with all the parts.

Ended up deciding to replace:
  • all the bolts
  • hub seals
  • a-plates (they were actually fine but the bronze bushings were shot)
  • king pins
  • spring
  • shocks
  • steering rack

I decided to keep the existing bearings after looking at the prices. I figure i will try and make them work, if they don't i will just replace the entire hub for the same price as 4 new bearings. I however underestimated the smell of ancient grease coming out of the old bearings. I had to take few trips for fresh air.
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Old 01-29-2018, 10:19 PM   #5
cobolnofun
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Default Re: My Winter* Project: a 1990 ds

Next up was frame repair.

So i originally planned to take it to a welder, but then thought i can braze this even though i have no idea how to braze things.

You can see the damage up by the bumper. Whatever accident they were in was actually strong enough to shear one of the bolts that holds the shock tower to the spring plate.
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Old 01-29-2018, 10:26 PM   #6
cobolnofun
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Default Re: My Winter* Project: a 1990 ds

brazing aluminum is hard. it is dang near impossible to get it up to temp with a propane torch on that i beam.
  1. Attempt 1
  2. Result of attempt 1: absolute failure. second i took the clamp off it snapped
  3. Attempt at the bumper: success i think?
  4. Attempt at other side of bumper: less success

I attempted the back support a few more times and was never able to get the i beam up to temp. So i thought about it with some beer, found some angle stock and came up with a solution. I wont say its a good one, but it is a solution.
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Old 01-29-2018, 10:34 PM   #7
cobolnofun
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Default Re: My Winter* Project: a 1990 ds

Ok last update for today: front end is back together. I did not realize how poorly this thing was actually handling. It is night and day driving it around the neighborhood. I have the alignment close but still need to tinker with it a little bit.

Waiting for the rear suspension parts to come in to tackle that.

After suspension i am kinda up in the air about whats going to happen. The only other requirement i have is headlights, which requires me to get a 93+ cowl and i am struggling to find a used one.

If i kind find one, i will upgrade to a solid state.

If i cant, i may go with a spartan body and hold off on the solid state.
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Old 03-01-2018, 10:10 PM   #8
Noonan
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Default Re: My Winter* Project: a 1990 ds

Looks like it's coming along nicely,it should be solid once you're finished.
What are your other plans for it?
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Old 03-02-2018, 02:41 AM   #9
spriddle
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Default Re: My Winter* Project: a 1990 ds

Looking really good so far. You've done a lot work!

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Old 03-02-2018, 10:37 AM   #10
ecaldwell78
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Default Re: My Winter* Project: a 1990 ds

Keep at it Cobo! Your hard work will pay off for sure. Great job so far!
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