My 2008 Ezgo PDS Build

tcald429

Hey all, been on the site for a while but have never posted. Have received alot of good information and cool ideas here, and wanted to share with you all my project i started a few years ago, and am just getting around to completing...

I worked at a local golf cart dealer during college, and had the opportunity to purchase a wrecked 2008 ezgo pds from a customer for $100. The cart had been wrecked on the front end, the body and frame was still intact, but the front axle was bent, an ear of the steering box was broken, shocks were bent, and tie rod was bent. The cart had also seen some severe damage from a dog with a chewing problem...including the seats, steering wheel, dash, and pedals. Needless to say, the cart needed alot of work, but I knew $100 was a steal considering the extra parts we had laying around the shop and my ability to get discounted parts. The cart also needed new batteries, as maintenance had been neglected and they were seeing much run time on a decharge test.

Here's a list of all that has been done to the cart:
-Stripped down to the frame and the entire frame has been cleaned and repainted.
-Replaced front axle, shocks, tie rod, and all bushings through out.
-Replaced the steering box housing and rebuilt with parts from old box.
-Replaced factory ezgo dash assembly, shock cover, rocker panels, rear bumper, and steering wheel.
-New 2 position ignition switch for lights, and new forward reverse switch.
-Installed a freedom upgrade chip.
-Added a set of 10" wheels and low profile tires we had laying around.
-Had the body repainted black (still need to paint the roof, thinking of going hotrod style with a silver or red metal flake and some pinstriping).
-Used some old seats laying around the shop and recovered with new black vinyl.
-New set of US Batteries, replaced all battery cables, and other wiring/ends as needed.

With what I have paid for the cart itself, all of the parts, a new paint job, and new set of batteries...I have about 1500 dollars in this project and have a 2008 PDS that is like brand new. The bulk of the expenses went into a set of batteries and the paint job which totaled about 1000.

Unfortunately I can't find any before pictures of the wrecked damage, or the mess that the dog had made. I tore into it and didn't even think about it. But I do have a few pictures of it stripped down, and how it sits now.

After stripping down, wreck repairs and new rims.


Finished college, moving on to a new job, and golf cart headed home for the first time from the shop. You can also see the new dash and steering wheel in this picture.


Me and the woman riding in style, told you the dog tore up the seat!!


And as it sits now, finally painted and beginning the reassemble process. Waiting on the painter to do some buffing, and need to find rivet gun cable of 1/4" rivets to finish attaching the body. Then it's on to the roof.


I will continue to post more pictures as the build progresses.

BGW

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monkey-1

Great progress on the rebuild. Can't wait to see it completed. Keep the pics coming.

HEAVY&LIFTED

Starting to look great , can't wait to see the finish product.

scottyb

We love our 08 PDS. We put 7 fresh 6v in it and a 400 amp Alltrax. She runs sweeet. Your looks like it will be as new when you are finished.

tcald429

Thanks guys, few updates...





Still need to paint the roof, and get the rest of the seat finished, but it's really coming together good. We just made our first trip to the local grocery store on it, really enjoyed the ride. Glad I stuck with this project.

Next on the mod list:

Paint the roof (thinking of metal flaking it for the hot rod look)
Flip-flop back seat
Stereo

monkey-1

Cart is looking better and better. Keep the good work up. That thing is going to be brand new when you are done. A chopped top would look awesome on that thing too!

MuckSavage

That looks great! You're a brave man for painting it black!