More Robust/Durable Roof Supports

[superpro56]

So the aluminum roof supports on my 96 CC have a bad habit of cracking and breaking, so far only low near the mounting points of the front cowl. Is there any recommendations on how to make these thing last longer than a couple trips? The cart usually sees somewhat rough terrain, but there are plenty of other similar carts without the issue in the same area. Anything I can do for vibration isolation or maybe fabricate my own, would like some ideas from people who have experienced this issue.

[Mooncarter]

Show us a photo of what you have. What type rough use are you talking about?

[mpr3369]

I switched to the newer style roof supports. They are steel and the newer roofs are much sturdier.

[superpro56]

Originally Posted by mpr3369

I switched to the newer style roof supports. They are steel and the newer roofs are much sturdier.

Where did you get the newer style supports?

[superpro56]

Originally Posted by Mooncarter

Show us a photo of what you have. What type rough use are you talking about?

The support keeps breaking just after it bends on the vertical portion. The terrain is usually unpaved trails, some ruts.

[Skoal82]

Do you have a welder or access to one.
Make them out of 1” steel tubing.
Copy original design, just square off the corners and maybe put a gusset in the bottom and top corners.

[mpr3369]

Originally Posted by superpro56

Where did you get the newer style supports?

I got them from a local golf cart parts store. The roof was a used roof from a different brand golf cart but it fit great.

[superpro56]

Originally Posted by Skoal82

Do you have a welder or access to one.
Make them out of 1” steel tubing.
Copy original design, just square off the corners and maybe put a gusset in the bottom and top corners.

That is a possibility. I need to do something, these aluminum ones have broke twice.

[Skoal82]

Most carts I buy are pretty ruff with no roof. I usually order a windshield first and make roof supports to fit. The txt carts are a little harder with the angle going from wider at bottom to narrower at top. Club car and Yamaha are much easier. It really makes the roof much sturdier than the aluminum supports.

[Fairtax4me]

The 2000+ DS carts use steel roof supports from the factory and they'll bolt straight onto your cart, but you need the supports and the roof.
They tend to be expensive to buy new. Used is the better way to go if you can find them. Check with the cart dealers in your area, especially ones that do upgrades and mods because they're likely to have a few take-offs from project carts.

One thing that can make the front ones crack is if the rear struts are loose. That makes the roof wobble a lot more than it should. My fix for that is to drill another set of holes in the supports about 2" forward of where the bag holder bolts on. Stick a 5/16 x 1-1/2" bolt through with washers on both sides and a lock nut and tighten it down.

Another thing you can do is cut a couple pieces of steel or aluminum 1/8 x 1" about 7-8" long, and bolt them on at angles across the lower corners of the front support.