97 Club Car DS 48v Restoration

[Swan]

when looking to replace the F/R switch with a heavy duty one , the other option is to go with reverse contactors and NEVER worry about again . it wont care how big of a controller you put in or largest torque or speed motor made for your cart .

[jbarsn]

Hey guys, it's been quite a while since I've updated this thread! I have made some progress on the rebuild and things are starting to come together!

After spending hours restoring the original front end parts, I decided to install a 6" lift. The lift was simple to install however the bushings on the rear leaf springs were an absolute PITA lol. I was also able to clean up and repaint some of the rear end parts.

I have attached some photos of installing the lift :)

[jbarsn]

I purchased a roll of 2awg cable in order to make my own upgraded cables and to redo the existing wiring.

I also purchased an Alltrax 400 amp controller (SPM48400) and a 400amp solenoid. The Alltrax manual says I need a fuse, resistor & and diode to install the higher amp controller and solenoid. Are these all required and necessary?

I will also be purchasing an SW202 reverse contractor to upgrade the stock F&R switch.

At that point, the cart will have an upgraded controller, cables, solenoid, F&R switch and should be ready and capable of handling an upgraded motor with 22" tires.

[simicrintz]

Lookin good!!!

[LukeL]

Looks great so far!

[Caseyrollins08]

I've enjoyed your post! Thanks for sharing!!

[DaveMJ]

What motor did you go with? You mentioned EMP earlier in this thread, I've purchased a few motors from them and been very happy with them.

[jamoore]

Just finished reading your thread. I am doing basically the same thing. Total basket case 98' DS. Your pictures look a lot like mine. My battery tray was also pretty toasty. I was planning to do what you did and actually ordered the aluminum. Since then, I stumbled into a super deal on 2 new, never assembled DS frames. I am in the process now of swapping over my front end and rear end/motor. Unlike you, I am pretty confident all my electronics are junk. I plan on using a kit from one of the sponsors to make it all brand new. I might be getting a little ahead but I ordered the seat covers today from Uptopar. Already picked my paint color and got it ordered and in hand. I am having fun and not in any rush. Here is a shot of the old frame being stripped and parts swapped to the new one. Keep up the great work, I will be following.