2015 Precedent Stretch Kit build w/ photos

RThelle

First time cart owner who decided that the 4 seater cart I purchased 4 weeks ago wasn't big enough for my family of 5. Don't worry - I knew all along I was going to stretch it. I took a day and drove up to see David(Tahoedawg) at Revolution Golf Cars to pick up all the items I needed to stretch the cart including the kit, top and extra seat to be recovered to match the others.

I wanted to detail the build as I thought it might help someone that was struggling to decide if they wanted to take on a project like this.

Here is what I started with:
2015 Precedent

Attached Images

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BGW

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RThelle

I'm not going to detail removing all the pieces to get it down to the f=rolling frame. I can tell you it took approx 3 hours to get it to bare frame. I don't know if that is fast or slow but I took my time labeling everything. Each set of bolts were placed into a ziploc bag and labeled. Staying organized is a HUGE part of a project like this.


I rolled the chassis outside and covered it in degreaser. I washed down everything and used brushes to get into the hard places. I figured I am never going to have a chance to get alot of these places cleaned up so might as well get it all shiny and new before I roll it back inside.

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RThelle

After detailing the frame and all the components, I rolled it back inside for some final cleaning. Majority of the components are aluminum however the front dash support bar and associated brackets are steel. Mine had some light rusting on them. I wire brushed the rust areas and the washed them down with OSPHO to treat the rust. After dried, I painted the pieces with black paint.

At this point, the chassis is inside the shop and ready to start the layout before cutting the frame.

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LukeL

Looks like a fun project. I stretched an EZ GO once. Looking forward to seeing more pictures.[emoji1303]


Club Car DS driver’s club #59

RThelle

The stretch kit I bought from Revolution Golf Cars seems straight forward. It goes without saying that you measure MULTIPLE TIMES before you drill the holes or cut the frame. The measurements are taken from the rearward most hole of the center crossmember. You remove the crossmember(goes right back in later). You can leave the brake cables attached. I ended up removing the driver side anyways because I needed to replace it with the longer cable since the cart is lifted. I'm not a fan of the brakes applying on their own as I hit bumps because the cable is pulled tight.

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RThelle

Frame is cut and ready to roll apart. I started with a reciprocating saw but realized I didn't like the "wobble" when it gets started and it wasnt going to have a clean line. I switched to a cut off wheel. My buddy is a welder/fabricator and is a surgeon genius with a cut off wheel

Once the frame was separated, we beveled the edges of the frame and of the new frame insert. I know everyone says that the frame extensions don't seem to flex or "give" any. However, since we tig weld in the shop, I wanted to go above and beyond with a full frame weld once the frame is squared up and level.

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RThelle

Rails spread forward and getting cleaned up for inserts

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RThelle

New rails are in. Taking our mandatory 15 minute break while we think about the fact that we just cut a perfectly good golf cart in half.

They slid in nicely. Since I didn't realize how the frame extensions were built I will explain it. Unfortunately, I did't take a photo of the pieces but its easy to understand.

The frame rail extensions come in 4 pieces. Each side gets 2 pieces.

Let's talk about one side. After you cut the frame, you spread it out and get ready to slide in the new one. (Sizes are approx) You get a 36" frame rail which is what you see in the last photo. You also get a 50" INSIDE frame rail. The 36" rail slides over top of the inside rail and gets centered. What you end up with is a 36' frame extension with 7" or so sticking out each end. These pieces sticking out are what slide inside of the front and rear frame rails.

Other side is exactly the same

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RThelle

Once all the bolts are in place(loosely) we lowered the cart back down so it was sitting on its own suspension. Quick shout out to Go-jaks for making this super easy and for allowing us to roll the cart around the shop as needed no matter what stage of the build we are at!

We used a level and straight edge to make sure everything was square before we tightened the bolts up.

Here is a close up of one of the joints. I was pleasantly surprised that there doesn't seem to be much, if any, frame flex once bolted together. As I said before, we are going to tig weld the frame today.

More photos coming tonight once we start re-assembly!!

(Big shout out to @motorvisions for holding the cart frame vertically so I could take this picture)

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TahoeDawgZ71

Looks good man! We thank you for the business. Can't wait to see what it looks like when you're done.