05-02-2021, 04:15 PM | #1 |
Not Yet Wild
Join Date: Jul 2017
Location: Manteno, IL
Posts: 55
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1996 Club Car DS - RoyPow Lithium Upgrade
Hey All! Sorry, I was hoping to post this as I was building it, but took a bunch of pics along the way. I got this cart (1996 Club Cart DS Electric) 4 years ago when I bought my house.
It had been used and from what I could tell, the Crown batteries that were in it were made in 2011. It ran pretty decent for the first couple years, then last year, it started dying out very quickly, even after a night of charging. Alas, one sad morning I went to take the cart out, and nothing. 2 of the batteries had finally died and were under 5 volts each. Charger wouldn't even try because they were too low. I will say though, for those LA batteries to last 10 years is pretty impressive, although, we only use our carts around here half the year. I had been planning to upgrade to lithium when the batteries died. So... Battery: RoyPow S51105 48V 105AH Purchase Date: 3/17/21 Completion Date: 5/1/21 Added the new battery Painted all black trim Made the new seats Added a new steering wheel Added a new steering assembly Added a 2nd power reducer Added a fuse box for all electronics Added a horn Added USB ports Added illuminated rockers Added a light bar Changed the old Halogen light bulbs to LED Added storage compartments and battery cover I am extremely pleased with the results, and the performance of the battery so far. I'll update this as often as I can for the next month or so to give some additional information or personal review details. Thank you to all of you on here - tons of information and some REALLY knowledgable folks - I'm not sure if I would have taken the leap to do this all myself without some of that shared information. The battery swap was fairly easy, just had to make my own bracket. The rest of the wiring was the hard part. I also tried to remove the OBC completely, but got it down to the last 3 wires and not sure what to do with them. One black 10ga to the controller, and a 14ga red and yellow to the solenoid. At least it is bypassed and moved to a better position. Thanks! |
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05-02-2021, 08:38 PM | #2 |
Gone Wild
Join Date: Apr 2020
Location: Hurricane, Utah
Posts: 2,802
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Re: 1996 Club Car DS - RoyPow Lithium Upgrade
What a great looking cart-well done!!!
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05-03-2021, 12:51 PM | #3 |
Not Yet Wild
Join Date: Jul 2017
Location: Manteno, IL
Posts: 55
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Re: 1996 Club Car DS - RoyPow Lithium Upgrade
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05-03-2021, 09:13 PM | #4 |
Gone Wild
Join Date: Apr 2020
Location: Hurricane, Utah
Posts: 2,802
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Re: 1996 Club Car DS - RoyPow Lithium Upgrade
Loose ends and tidying up help to keep you out of the clubs (and trouble) at night!
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06-07-2021, 01:51 PM | #5 |
Not Yet Wild
Join Date: May 2021
Posts: 7
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Re: 1996 Club Car DS - RoyPow Lithium Upgrade
Is it advisable to have the Lithium battery mounted at an angle like that? My install guy said he can't install the RoyPow because the tilt in the chassis would make it unsafe.
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06-07-2021, 02:48 PM | #6 |
Gone Wild
Join Date: May 2012
Location: Rio Verde, Az
Posts: 7,193
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Re: 1996 Club Car DS - RoyPow Lithium Upgrade
Lithium batteries do not care what angle they are mounted at. If they fit, then the angle should be fine.
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06-07-2021, 05:43 PM | #7 |
Gone Wild
Join Date: Oct 2012
Location: Southwestern Pa.
Posts: 6,215
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Re: 1996 Club Car DS - RoyPow Lithium Upgrade
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06-09-2021, 03:29 AM | #8 |
Not Yet Wild
Join Date: May 2021
Posts: 7
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Re: 1996 Club Car DS - RoyPow Lithium Upgrade
Is it ok to mount the lithium on an angle like that?
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06-09-2021, 03:30 AM | #9 |
Not Yet Wild
Join Date: May 2021
Posts: 7
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Re: 1996 Club Car DS - RoyPow Lithium Upgrade
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06-19-2021, 09:21 AM | #10 |
Not Yet Wild
Join Date: Oct 2020
Location: Arkansas
Posts: 1
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Re: 1996 Club Car DS - RoyPow Lithium Upgrade
Where did you find your roypow I'm trying to find a dealer that won't mark it up $500
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