Another G3 SunClassic modernization/48v conversion.

[cgtech]

Time for another G3 SunClassic conversion to 48v. This conversion is for a customer at work, not my own personal cart. I have always wanted to modernize a SunClassic. The stated goals are as follows, improved speed (24-25 mph goal), improved power, improved efficiency (achieved with a solid state motor controller instead of wasteful resistor coils). All while maintaining as much original operation and features as possible, keeping the instruments and key switch F&R controls intact. I have a plan laid out to achieve all these goals except not sure about one (the function of the low battery light). All the instrumentation operates from 12v, which is really good for me. Also working in my favor is the fact that club car 10-spline motors bolt right up to the Yamaha axle used in 99% of 36v Yamaha carts, so there are plenty of motor options. I will be going the SepEx motor route, because I consider it less complex to use with the keyswitch F&R, and its slightly less cost based on what I already have on hand to use, and I hope Regen braking will help range a little. I suppose next I will list materials I plan to use.

- Alltrax xct-48400-pds motor controller
- Yamaha 48v solenoid from early YDRE (trombetta, 225a continuous rating)
- 2ga cables everywhere
- 6x Trojan T-875 8v batteries
- PB-6 throttle sensor
- DPI 48v charger
- DPI DC/DC converter
- Admiral mot-a2

My first step was removing the batteries, the resistor coil assembly, and the throttle wiper assembly. This is pretty easy, because it's all mounted to the same bracket. Throttle linkage, a few wires, and a couple bolts.

More to come soon, photos, and changes as needed.

[LukeL]

This is great. Can’t wait to see this build!

[Mooncarter]

Originally Posted by LukeL

This is great. Can’t wait to see this build!

X2!

[cgtech]

Some pics of the bracket with new stuff.

[LukeL]

Originally Posted by cgtech

Some pics of the bracket with new stuff.

I also used a PB-6. Looks nice.

[scottyb]

Pot boxes are okay if you keep them dry

[cgtech]

Originally Posted by scottyb

Pot boxes are okay if you keep them dry

Funny you mention that, I made shielding for it that didn't make it into the pictures. I have "experienced" that same phenomenon you speak of.

[LukeL]

Originally Posted by scottyb

Pot boxes are okay if you keep them dry

Originally Posted by cgtech

Funny you mention that, I made shielding for it that didn't make it into the pictures. I have "experienced" that same phenomenon you speak of.

Mine does ok mounted really close to the bottom. I've gotten it pretty wet too. I'll have to keep an eye on that.

[scottyb]

Originally Posted by LukeL

Mine does ok mounted really close to the bottom. I've gotten it pretty wet too. I'll have to keep an eye on that.

We used the PB6 in our conversion kits for many years and most people do okay with them. Ezgo used them in the early 90s and CC even used em for a couple of years. When they get water into them the output goes silly and the controller gets confused. Often a hair dryer can fix them. GC is going to love the solid state oldie

[cgtech]

My ole marathon got wet once, driving through 4" of water, it stayed at full throttle. My bro didn't know about "neutral" and it wacked a pole. Luckily that was a easy one, only needed a new front leaf spring.