The Making of a More Masculine PDS

K2merckx · 04-21-2011, 11:20 AM

After scouring these forums and lurking for a few months I decided that it was time to post my build thread. Initially I was just going to paint the body of my 2001 PDS cart and replace the batteries...... But we all know how that turns out.

So this is my almost to frame rebuild of the cart stating with some before pictures. The cart was is pretty good shape, but since a recent break up I thought it was time to change the color.

Before Pics:

K2merckx · 04-21-2011, 12:28 PM

Initially I was going to stay 36v and run it for another season. While trying to work on the batteries I had a little issue so the full 48v upgrade was starting to take shape as well as motor and controller.

K2merckx · 04-21-2011, 12:44 PM

While I had all the batteries out and access to the whole back end I cleaned up some rust spots and hit it with a little Rustoleum Black paint. Motor is on its way to Plum Quick and changed the rear leaf springs to the Heavy Duties.

DOOmsman · 04-21-2011, 12:56 PM

I was going to say find a new friend but realized you did take the cheaper route.

Keep us posted, the frame looks good with a coat of paint.

K2merckx · 04-21-2011, 01:04 PM

After talking to Scottyb while picking up my new 8v batteries I got to thinking about a little brake upgrade. I literally hadn't finished my drive home from Carts Unlimited and was back on the phone with Scotty ordering up the new two wheel hydraulic disc brakes.

I had them within a couple of days and was I ever impressed. They are well made and I was going to feel a lot better about stopping after basically doubling the speed of my cart.

Installing the brakes was fairly easy but I did create some issues for myself. Here is a little hint I am going to hand out for free. When taking the drum off your old brakes, it is far EASIER to NOT HAVE THE PARKING BRAKE ON

Sometimes I question my mechanical skills???

It was a great day because in the middle of the brake install my greasy hands dropped the camera and breaking it.

K2merckx · 04-21-2011, 01:06 PM

You are oh so Right, Dooms. In the process of finding new friend but it was really my excuse to have a little fun project to work on.

K2merckx · 04-21-2011, 01:11 PM

Here is some of what was happening to the body while I was working on frame and parts. My friend is painting the body for me and he was trying a water droplet effect on the top. Very cool, but unfortunately on silver it just makes the cart look dirty. So we decided against it.

K2merckx · 04-21-2011, 01:22 PM

Time to make the 48v upgrade. Here are the new 8v batteries. I have since changed the layout of the batteries so that the cable between 24v and 32v is shorter.

By the way I realize that the cable I am using is not welding cable but I had 2ga wire sitting around from some stereo installs so I decided to save a little dough and build the cables. I will run them till they break. Then I can spend the extra $200 or so on the good ones.

Also had a chance to throw the new Alltrax 500amp controller in.

K2merckx · 04-21-2011, 02:43 PM

Not too long after installing the batteries, controller and cables the Plum Quick motor showed up. The motor was a pretty straight forward install.

K2merckx · 04-21-2011, 02:55 PM

Now it was time for the fun electrical components. I had a few ideas in mind but wasn't exactly sure how to incorporate them into the build.

I have to give a very special thanks to todo_brane_ded

He had patience with me with some pretty remedial electrical questions. And if you have seen some of his posts on here you know he knows what he is talking about.

Basically wiring up a stereo, interior lighting, exterior lighting with a 3 position round key switch. I also installed a fuse block inside the drivers side glove box. I know some have installed it under the front cowling but for whatever reason I wanted access to the fuses. Crazy I know.

04-21-2011, 12:56 PM	#4
DOOmsman Gone Wild Join Date: Jul 2008 Location: Reddick IL Posts: 11,220	Re: The Making of a More Masculine PDS I was going to say find a new friend but realized you did take the cheaper route. Keep us posted, the frame looks good with a coat of paint.

04-21-2011, 01:06 PM	#6
K2merckx Not Yet Wild Join Date: Apr 2010 Posts: 51	Re: The Making of a More Masculine PDS You are oh so Right, Dooms. In the process of finding new friend but it was really my excuse to have a little fun project to work on.
K2merckx Not Yet Wild Join Date: Apr 2010 Posts: 51

Similar Threads
Thread	Forum
making a plow	Lifted Golf Carts
need help making first purchase	On Road Golf Carts!
Making your own	Design Center
Making my g16 idle ? Can and should it be done ?	Gas Yamaha

Today
BGW	Sponsored Links __________________ This advertising will not be shown in this way to registered members. Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum