87 Club Car DS modernization project

[Bobbob]

It looks like you are still using the resistor on the large posts of the solenoid. I though the Alltrax didn’t require that anymore? Instead they now require a diode in its place. Or maybe you just didn’t change it yet on the picture.


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[ACCLR8N]

Originally Posted by Bobbob

It looks like you are still using the resistor on the large posts of the solenoid. I though the Alltrax didn’t require that anymore? Instead they now require a diode in its place. Or maybe you just didn’t change it yet on the picture.


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The resistor was included with my solid state conversion kit and installed according to the provided wiring diagram. Carts Unlimited C54.

[Sergio]

Alltrax Series controllers still use the resistor, looking good

[ACCLR8N]

Originally Posted by Sergio

Alltrax Series controllers still use the resistor, looking good

Thank you Sergio. The lithium power source would not have been possible without your detailed explanation, diagrams and parts list. Much appreciated. I haven't seen anyone go to the lengths you have just to help out fellow enthusiasts.

[ACCLR8N]

I have been working on suspension. Boring stuff. King pins, bushings, steering joints, control arm, shocks and lots of rusty bolt replacements.

I went conservative on my wheel and tire choice to keep lots of hill climbing torque and a low center of gravity. There is a famous family story of my daughter making it exactly halfway around our house before rolling our brand new go-cart. How do you roll a Yerfdog?

[Noonan]

Originally Posted by ACCLR8N

..... everything else is going over budget.

Uh huh.
You should just go ahead and get used to that now.

Good luck with your project and keep us up to date!

[ACCLR8N]

I made some lift brackets for the rear springs. I also installed some heavy duty springs. They are way too stiff. When I step on the back of the cart it doesn't budge. I am thinking about taking the middle leaf out. Anybody think that is a bad idea?

Pictures upside-down?

[ACCLR8N]

New seats are in and installed. Switched to the one piece seat back as there tends to be a granddaughter in the middle.

Wife is into this project and pushed me to order Spartan body kit to finish it off.

[ACCLR8N]

Rebuilding the front end I came across a couple factoids to share:

1987 upper kingpin clevis bracket replacement you can use the 1993+ by drilling out the holes to fit the older shoulder bolt.

1987 Short shoulder bolt at the outer clevis, everyone lists this part for Gas club cars only. It fits my electric.

The entire 1987 rack and pinion steering system will bolt onto a 1983 pitman arm frame. Same steering box holes and everything.

Dorman 610-138 wheel studs will give you that extra bite you need (0.535 knurls) to install in those warn axle flange holes.

You need a 3/4" reamer to replace the kingpin bushings.

New bushings, wave washers, kingpins I ended up slipping an extra shim washer in the top of the stack as it still had to much play up and down.

[simicrintz]

Originally Posted by ACCLR8N

Wife is into this project and pushed me to order Spartan body kit to finish it off.