Club Car DS Lithium Conversion

[Furyous]

Made significant progress last night but still not done.

Got the underwear lights wires up- they look fantastic with the frame rail lights.

Wires up the Harley-Davidson ignition switch. This gives us two positions: one for accessories, then one more engages the controller and puts the cart in run mode.
Got the BMS wired up and working.

Painted the inside of the body- just went with a plain semi gloss black, but tried to do something artistic and failed. Will repaint in plain black later. It’s just too much and came out a bit cheap looking.


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[chris1832]

Looks great!! What on board charger did you use?


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[Furyous]

Something my buddy got on amazon but it’s the same Chinese one I got on eBay. 10 amps. Dead to full in three hours. I have had mine for probably 1500 miles and love it.


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[chris1832]

I just ordered one for mine. Hopefully have my lithium conversion complete by next weekend!!


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[Furyous]

Originally Posted by chris1832

I just ordered one for mine. Hopefully have my lithium conversion complete by next weekend!!


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That’s ambitious! It could be done, but new wiring and the fab work, plus every time you take something else apart you think of a new custom touch to do.


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[chris1832]

Your absolutely right. Hopefully I’ll have it back up and running soon.


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[Furyous]

Got it running last night!!! Momentous occasion. Just had to wire up the forward/reverse switch to the contactors and off it went. Still have problems with the MCOR only dishing out 61% throttle, so it hit 14 mph only. When we took the MCOR off and moved it manually, it was limited to 79% throttle. We tried many different configurations with the controller programming but it appeared the MCOR was the problem.

We put my old potentiometer on it and programmed it for 0-5k ohms, it showed 0-100% right away. We decided to try it like a handicapped throttle and maneuver the throttle manually and use the foot pedal to activate the contactors. Suddenly it ran great. 24 MPH with 54.5 v.
We also programmed the LEDs to be a light blue-green. A cool but unintended result of the gaps between the floor panels was this awesome lighting effect underneath.


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[DaveTM]

Nice work!

[Ribfeast]

Well done! Love the artwork, and clean build. How much more punchy is it with the lithium!

[S4TA]

May be a dumb question, but what is the part holding the Anderson connector off of the box made of?


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