97 Club Car DS 48v Restoration

[jbarsn]

Hi guys! I picked up a 97 CC DS a few months ago for just $150. She is definitely a little rough and needs a lot of work lol



I've never had a golf cart nor have I ever worked on one. I've made lots of progress and have been taking lots of pics to document the entire process! I will update this thread frequently with the rebuild progress.

Here are some pics from when I picked her up!

[jakesnake27]

You've got a great foundation, have fun with it!

[jbarsn]

The owner told me it last ran about 3 years ago and has been sitting outside since. My first challenge was removing the rusty bolts and nuts. I ended up drilling out most of the phillips screws holding the body onto the frame.

Here are some pics after the body was removed and the cart was cleaned up.

[jbarsn]

Originally Posted by jakesnake27

You've got a great foundation, have fun with it!

Thanks! For the price I paid, I couldn't go wrong! It has been a fun project so far and cannot wait for the end result! I have put a decent amount of work into the cart the last few months but it is not anywhere near complete.

Stay tuned as I will keep this thread updated with all of my progress

[jakesnake27]

Yep, gotta love the ones you can grab cheap! Can't wait to follow along.

[Mooncarter]

Looking good!

[Swan]

with you in it for so little means you can do so much more, love a good blank canvas .

[jbarsn]

After giving the cart a thorough cleaning and inspection, I decided the battery tray would be the first repair.

I sawed out the old corroded rails and replaced them with new aluminum angle. I believe 1/8"

I still need to find and install new battery hold downs.


After the repair was made, I purchased 6 new 8v batteries. I fit them into place and used some 6awg cable to connect them all together.

Like I mentioned earlier in my post, I had no experience with golf carts whatsoever. After looking over the cart, it seemed like everything was there and in place. I noticed the cart did not have any keys and the ignition was completely corroded. I replaced the whole ignition, powered up the cart and was amazed to see the wheels turn! I honestly did not expect the cart to run!

This was a huge relief as I realized the original $150 spent was now a great investment!

[jbarsn]

I plan to add a top and possibly a rear seat. I also would like to get larger wheels and eventually a 3-6" lift. Before I go crazy and upgrade the cart, I want to do a proper restoration.

After just removing the body, I realized every part on the cart was either rusty or corroded. I prefer things nice and new lol so this is just the beginning of the restoration project.

To start, I decided to disassemble the entire front end. I am currently sanding away all the rust and repainting all of the parts.

I then plan to do the same to the rear. While I am working on the rear, I am considering removing the motor and sending it out to Plum Quick so they can do a proper rebuild and tune up :)

Once the front end and rear are completed, I will then move onto the electrical system. I will replace all of the old cables with 2awg. I also plan to DIY upgrade my F&R switch. This should allow me to upgrade my controller if I ever decide to.

[jbarsn]

Here are some photos of the front end being taken apart and slowly restored :)