Lipstick on a Pig Budget Club Car

Furyous

Have a friend that has a $2,000 budget but wanted a reliable golf cart that she can upgrade later. Found this club car for $500 that needed batteries. Has the extended roof and rear seat.

Got new seat covers, seat belts, batteries, leaf springs, bushings, shocks, brake cables, and wheels and tires for about $1200 more and will lay a coat of paint on the roof and body with $30 of paint.


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BGW

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Furyous

I reversed the rear wheels to widen it a bit and added 1” wheel spacers I had laying around to widen the front to match the back. Looks much sportier. Tore it down, wire brushed the battery trays, removed the rear suspension.


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Furyous

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Furyous

Soldered and crimped new lugs and ring terminals on the wires. The lugs on the motor had ferrous nuts on them and just disintegrated when I tried to loosen them. Good thing I had a spare motor lying around. Also, the commutator was fused to the shaft. I had to use a pickle fork and a three pound hand sledge to get it off. The bushings were completely non existent.


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Furyous

Someone riveted aluminum plates that say “beware of dog” on them to replace rotted battery trays.

She wants this thing done by Halloween so I’m hoping to have it together and painted before the seat covers come in on the 22nd.


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LukeL

Hey- you’re getting full time into this! Love your builds. Nice work.

gotti

Nice job on the rebuild, so far. Keep the pictures coming.

jakesnake27

Good progress so far!

Furyous

Getting further. Man I got a lot of hours in this thing already but I want it to be done and done well.

Seat covers came in. They were only $70 a set with free shipping on eBay. I had to cut new plywood seat bottoms from scrap wood because both were rotted. I gave them a coat of satin black to dress them up a bit.


I left the seat covers in the sun on the black driveway so they would be nice and stretchy, then started with the seat backs. The customer chose these two colors of grey- I think the combination looks great.
Here’s a before and after:

Then I moved on to the seat bottoms. Doing the seat backs first gave the paint time to dry.
I’ll tell you though, after pulling all the staples out of the old covers, putting the new ones on and pulling and stretching the vinyl into place, my hands were chewed up with blisters and scrapes. The end result was great.

The outside grey if these seats is an exact match for some grey primer rattle cans I have, so I am going to repair, sand, and spray the body with it. Then, 400 grit wet/dry, then a couple coats of clear.


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Furyous

Today I attacked the rocker panels. I never really liked the bare aluminum overload on DS models, so I sanded and painted them gloss black. That way they will match the wheels and the roof struts after they are painted too. I was worried about people stepping on the top ridge and wearing away the paint, so I put $10 worth of gloss black plastic self adhesive u channel all around.

I also took the rubber rub rails and cleaned them with warm soapy water and a brush, then treated them with maguires black treatment to get rid of all the sun fading. This pic is from before treatment- I’ll have to take another now that they are back on the cart.

I need to start reassembling the rear suspension, but I couldn’t let this rear end go in as is. Again, this is before but I was in a hurry so I didn’t get any after shots yet. I used a wire brush on an angle grinder and went to town cleaning up all the rust. I also took a lot of the corrosion off of the aluminum gear housing which brightened up nicely.


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