Solidstate conversion on 97 resistor cart

[97ccds-custom]

So I finally started my C54 conversion to solidstate that I purchased from ScottyB at Carts Unlimited.

I was a little nervous to get started but once the coils and vglide came out, I felt a little relieved as I'm all in now

[97ccds-custom]

Here are the original coils and the empty bay with the solenoid, vglide and coils still intact.

[97ccds-custom]

After wrestling with some rusted 23 year old bolts I finally got the old gear out and had an empty bay.

[97ccds-custom]

Using some 1.5" square angle aluminum I got from Amazon for $15, I manufactured a bracket to support the backside of the Alltrax SR 48500 speed controller that I used rivets to secure to the side, then I cut a smaller piece to make a bracket for the new 400A solenoid. https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

[97ccds-custom]

Now I'm a little stumped at trying to take out the "Go" Accelerator pedal. Looking at ScottyB's instructions it looks like carts that are 1995+ don't require the spring bracket that the kit comes with. My cart has this black plastic retainer and accelerator return spring connected to the rod that connects the brake to the Go pedal. But in order to install the new electronic Accelerator pedal I have to remove the old one. Does anyone have any idea what the easiest method is to remove the go pedal on a 95+ cart?

I know I basically need to slide the pedal off the pivot rod assembly, but I'm having a tough time figure out the easy path.

Using the diagram I removed 20,21,25 that attaches the pedal to #18. Then I removed nut #25 in the blow out on the otherside of the rod connecting to the bracket under the brake pedal and I even tried #22 behind spring that is the accelerator return to see if I could get part #18 to budget enough to slide off the pedal, but couldn't get the pedal to budge off the rod. So I'm thinking there is something I'm missing.

[97ccds-custom]

I think I have narrowed down the issue to something that looks like a compression sleeve on the rod in the hole that is on the bracket bolted to the frame on the side of the go pedal. It appear to be fused to the rod and that is preventing me from sliding it completely out. I pointing to where the sleeve appears to be in this attachment. Would appreciate any help for a newb. Thanks in advance.

[scottyb]

I have had a few people tell me they could not disassemble the newer style pedal due to (metal bonding) corrosion so they simply cut the pedal off under the floor and installed the new pedal above. This solution seemed to work fine for them. The step by step install thread on BGW is here > https://www.buggiesgonewild.com/showthread.php?t=134325

[97ccds-custom]

That's what I ended up doing, just drilled through and sawed off the bracket. Ironically, once I pulled the pedal off the arm, everything started moving freely, it could be all the rust eater and wd-40 I sprayed finally kicked in.

The existing hole was actually larger than the template for the e-pedal so I had to manufacturer a bracket for the hole furthest back. Time will tell if it holds or if I have to put something stronger.

[97ccds-custom]

Here's the finished pedal installed.

So now I'm prepped to start the wiring another day.

[97ccds-custom]

Picked up some 10g 48” black and white and 3 colors of 16g wire today to get started! Bill came to $20.
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