Cut access panel in body

golf cart man · 02-29-2016, 11:25 PM

Anybody with an old style fiberglass rear DS body without access panel ever cut one out? Did it affect the structural integrity of the body? I am looking at replacing my controller and motor and it would be much easier to see what is going on if I had an access panel like the newer Club car DS have. Thanks

tag50 · 03-01-2016, 01:45 AM

I cut an access hole in my plastic body while it was on the cart. The aluminum cross bars made it a real challenge.

.

golf cart man · 03-02-2016, 06:48 PM

im assuming that you had the newer style? mine has no access hole at all and its fiberglass

scottyb · 03-02-2016, 07:27 PM

Do you have the access cover you intend to use? Maybe you can hold that on the body and trace it with a pencil then cut inside that line 1/2 inch or so all the way around.
Or be safe, start in the middle with a modest size hole, and expand out once you can see (or feel) how much clear room you have.

golf cart man · 03-02-2016, 08:55 PM

Quote:

Originally Posted by scottyb

Do you have the access cover you intend to use? Maybe you can hold that on the body and trace it with a pencil then cut inside that line 1/2 inch or so all the way around.
Or be safe, start in the middle with a modest size hole, and expand out once you can see (or feel) how much clear room you have.

Thats a good idea! i was thinking of using a factory one that club car uses on the newer style bodies.

scottyb · 03-02-2016, 08:58 PM

Roger that - sounds like a plan

tag50 · 03-02-2016, 09:14 PM

Yea, mine didn't have any hole. I started with 3x12 hole. Cut out 3 holes before it was done. Use a pry bar and shims get more space between the body and the cross bars. Cutting was done with a Roto-Tool. I used a stainless steel cookie sheet for the cover.

If you use a Roto-Tool or a router wear eye protection, mask, long sleeves and gloves (fiberglass dust is nasty).

.

scottyb · 03-02-2016, 09:52 PM

Okay honey I'm going in....

golf cart man · 03-02-2016, 10:20 PM

Quote:

Originally Posted by tag50

Yea, mine didn't have any hole. I started with 3x12 hole. Cut out 3 holes before it was done. Use a pry bar and shims get more space between the body and the cross bars. Cutting was done with a Roto-Tool. I used a stainless steel cookie sheet for the cover.

If you use a Roto-Tool or a router wear eye protection, mask, long sleeves and gloves (fiberglass dust is nasty).

.

I'm still pulling fiberglass out of my arms from trimming the front body. I had never cut fiberglass before….I sure learned my lesson

golf cart man · 03-03-2016, 03:25 PM

Anybody willing to measure the dimensions of their club car access hole? I would greatly appreciate it.

02-29-2016, 11:25 PM	#1
golf cart man Gone Unrestrained Join Date: Aug 2008 Location: South Florida Posts: 1,300	Cut access panel in body Anybody with an old style fiberglass rear DS body without access panel ever cut one out? Did it affect the structural integrity of the body? I am looking at replacing my controller and motor and it would be much easier to see what is going on if I had an access panel like the newer Club car DS have. Thanks

03-01-2016, 01:45 AM	#2
tag50 Gone Wild Join Date: Apr 2014 Location: Oregon City, Or Posts: 1,977	Re: Cut access panel in body I cut an access hole in my plastic body while it was on the cart. The aluminum cross bars made it a real challenge. .

03-02-2016, 06:48 PM	#3
golf cart man Gone Unrestrained Join Date: Aug 2008 Location: South Florida Posts: 1,300	Re: Cut access panel in body im assuming that you had the newer style? mine has no access hole at all and its fiberglass

03-02-2016, 07:27 PM	#4
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Cut access panel in body Do you have the access cover you intend to use? Maybe you can hold that on the body and trace it with a pencil then cut inside that line 1/2 inch or so all the way around. Or be safe, start in the middle with a modest size hole, and expand out once you can see (or feel) how much clear room you have.

03-02-2016, 08:58 PM	#6
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Cut access panel in body Roger that - sounds like a plan

Today
BGW	Sponsored Links __________________ This advertising will not be shown in this way to registered members. Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

03-02-2016, 09:14 PM	#7
tag50 Gone Wild Join Date: Apr 2014 Location: Oregon City, Or Posts: 1,977	Re: Cut access panel in body Yea, mine didn't have any hole. I started with 3x12 hole. Cut out 3 holes before it was done. Use a pry bar and shims get more space between the body and the cross bars. Cutting was done with a Roto-Tool. I used a stainless steel cookie sheet for the cover. If you use a Roto-Tool or a router wear eye protection, mask, long sleeves and gloves (fiberglass dust is nasty). .

03-03-2016, 03:25 PM	#10
golf cart man Gone Unrestrained Join Date: Aug 2008 Location: South Florida Posts: 1,300	Re: Cut access panel in body Anybody willing to measure the dimensions of their club car access hole? I would greatly appreciate it.

Similar Threads
Thread	Forum
How to remove access panel	Electric Club Car
Access panel ?	Electric Club Car
WTB Access Panel from 93+ CC DS	Golf Carts and Parts
Access Panel	Gas Club Car
Access Panel -Marathon	Golf Carts and Parts