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Old 07-20-2017, 01:19 AM   #1
agpfl
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Default 2006 Series to PDS Frame Up Rebuild

I purchased a 2006 Series in early May and have been working on a frame up rebuild. I am converting to PDS and will build a lithium pack. I have been taking lots of pictures along the way and am finally getting around to posting them.

Here is the before picture in all its glory. No batteries and almost no battery tray left. Tore it all the way down to the frame. Removed everything from the frame and sent it off for sandblasting and powder coating.
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Old 07-20-2017, 05:32 AM   #2
03psd73
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Default Re: 2006 Series to PDS Frame Up Rebuild

Great looking start
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Old 07-20-2017, 06:54 AM   #3
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Default Re: 2006 Series to PDS Frame Up Rebuild

Which controller are you going with?
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Old 07-20-2017, 07:38 AM   #4
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Default Re: 2006 Series to PDS Frame Up Rebuild

Using a stock PDS controller to start with, but once I complete the built I will swap over my Alltrax XCT400 from my 2005 PDS daily driver.

Sent from my SCH-I545 using Tapatalk
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Old 07-20-2017, 07:43 AM   #5
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Default Re: 2006 Series to PDS Frame Up Rebuild

Looks great - When you say down to the frame, you're not kidding.
Are you going with the factory wire harnesses or making your own for the PDS conversion?
What motor will you be using? What voltage & amperage are you planning for the lithium pack?
What tires and wheels? - So many questions we have
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Old 07-20-2017, 08:31 AM   #6
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Default Re: 2006 Series to PDS Frame Up Rebuild

I was going to build my own harness, but a very generous BGW member donated the harness, f&r switch with console plate, and pedal box harness.
The rest you will have to wait and see.

Sent from my SCH-I545 using Tapatalk
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Old 07-20-2017, 08:41 AM   #7
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Default Re: 2006 Series to PDS Frame Up Rebuild

There are some very generous people here
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Old 07-20-2017, 11:48 AM   #8
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Default Re: 2006 Series to PDS Frame Up Rebuild

Quote:
Originally Posted by agpfl View Post
I was going to build my own harness, but a very generous BGW member donated the harness, f&r switch with console plate, and pedal box harness.
The rest you will have to wait and see.

Sent from my SCH-I545 using Tapatalk
Excellent on the harness Was just going to ask for that reason. I have seen pds wiring plugs out there now for people doing their own thing. Isn't that much to it if starting from ground zero.
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Old 07-20-2017, 11:55 AM   #9
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Default Re: 2006 Series to PDS Frame Up Rebuild

Frame and misc parts sandblasted, overall the frame was in really good shape.
Front suspension with 6" Steeleng drop axle lift and new steering gear box, springs were in good shape and not flattened, just needed cleaning.
Rear axle before any work was done to it. Notice the old and new battery tray on the right hand side.
Frame back from powder coating, starting to clean up nuts, bolts, and other hardware.
Brake pedal reassembled with new brake pedal pad kit. It was much easier to reassemble than to take apart.
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Old 07-20-2017, 12:07 PM   #10
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Default Re: 2006 Series to PDS Frame Up Rebuild

Quote:
Originally Posted by kgsc View Post
Excellent on the harness Was just going to ask for that reason. I have seen pds wiring plugs out there now for people doing their own thing. Isn't that much to it if starting from ground zero.
I had already tracked down the 10 position Molex housing https://www.arrow.com/en/products/1053082210/molex as well as the connector contact https://www.arrow.com/en/products/search?q=105300 and was prepared to make it myself.

BGW members are the best! Always looking out for each other and going out of their way to help others.
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