01-29-2018, 09:48 PM | #1 |
Not Yet Wild
Join Date: Jul 2017
Location: KC
Posts: 43
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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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01-29-2018, 09:53 PM | #2 |
Not Yet Wild
Join Date: Jul 2017
Location: KC
Posts: 43
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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 |
01-29-2018, 09:58 PM | #3 |
Not Yet Wild
Join Date: Jul 2017
Location: KC
Posts: 43
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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 |
01-29-2018, 10:06 PM | #4 |
Not Yet Wild
Join Date: Jul 2017
Location: KC
Posts: 43
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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:
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. |
01-29-2018, 10:19 PM | #5 |
Not Yet Wild
Join Date: Jul 2017
Location: KC
Posts: 43
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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. |
01-29-2018, 10:26 PM | #6 |
Not Yet Wild
Join Date: Jul 2017
Location: KC
Posts: 43
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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.
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. |
01-29-2018, 10:34 PM | #7 |
Not Yet Wild
Join Date: Jul 2017
Location: KC
Posts: 43
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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. |
03-01-2018, 10:10 PM | #8 |
Gone Wild
Join Date: Jul 2017
Location: Cape Coral FL
Posts: 243
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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? |
03-02-2018, 02:41 AM | #9 |
Admin
Join Date: Dec 2006
Location: TN
Posts: 101,826
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Re: My Winter* Project: a 1990 ds
Looking really good so far. You've done a lot work!
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03-02-2018, 10:37 AM | #10 |
Gone Wild
Join Date: Aug 2014
Location: Lebanon, Indiana
Posts: 203
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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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