2008 CC Carryall Rebuild

[CP241]

Originally Posted by BlueDubPirate

Got the steering wheel off thanks to some counter-intuitive advice. The "pound the bolt with a hammer" thing worked! Also planned to change out the rear suspension today but ran into a problem. I ordered the correct rear springs to replace my old, saggy ones but the company sent me the wrong springs! After wasting a lot of time trying to get them installed, I finally realized they were too short. Very frustrating. I'll have to wait 2 days for the clutch puller and 4 more days for my new springs. I'm stuck.

Hate having to wait for parts to arrive. Especially in the middle of something like that.

[BBBHC]

You might try a heat gun on those stickers, instead of solvent. I've done it that way on a Ranger I had years ago as well as on other things.

There is a guy in Texas looking for an engine. He posted the other day about it in the for sale threads. Can't remember if he was looking for a 290 or 350.

[BlueDubPirate]

Originally Posted by BBBHC

You might try a heat gun on those stickers, instead of solvent. I've done it that way on a Ranger I had years ago as well as on other things.

There is a guy in Texas looking for an engine. He posted the other day about it in the for sale threads. Can't remember if he was looking for a 290 or 350.

Great idea and great excuse to buy a heat gun!

[BlueDubPirate]

Please forgive me but I'm going to complain for a moment. One of my objectives with this cart is to cut down on the rattling and vibration noise. It is a carryall, but that doesn't mean it needs to sound like a rattletrap going down the road. As I've pulled this cart apart, I've noticed areas where former owners or technicians cut corners.

One thing I despise is laziness or worse, knowingly doing stupid things just because it is harder and sometimes more expensive to do it the right way. Case in point, when someone worked on the rear the springs, they didn't replace the bushings. So, you have metal on metal in a very high stress joint. How dumb. No wonder this cart has so much suspension noise.




On the positive side, I did notice quite by accident that the leaf spring bushings also perfectly fit the pivot points for the cargo box. Those too were missing from my cart and are now installed with stainless bolts and lithium grease, awaiting a new box. They will operate quietly and smoothly!

[BBBHC]

Originally Posted by BlueDubPirate

Great idea and great excuse to buy a heat gun!

I bought one from Harbor FRIGHT during my build for $15. Has 2 heat settings and seems to be good... We'll see...

Originally Posted by BlueDubPirate

Please forgive me but I'm going to complain for a moment. One of my objectives with this cart is to cut down on the rattling and vibration noise. It is a carryall, but that doesn't mean it needs to sound like a rattletrap going down the road. As I've pulled this cart apart, I've noticed areas where former owners or technicians cut corners.

One thing I despise is laziness or worse, knowingly doing stupid things just because it is harder and sometimes more expensive to do it the right way. Case in point, when someone worked on the rear the springs, they didn't replace the bushings. So, you have metal on metal in a very high stress joint. How dumb. No wonder this cart has so much suspension noise.



That's just ridiculously lazy and stupid! Your ride quality should be well improved, I would think!
On the positive side, I did notice quite by accident that the leaf spring bushings also perfectly fit the pivot points for the cargo box. Those too were missing from my cart and are now installed with stainless bolts and lithium grease, awaiting a new box. They will operate quietly and smoothly!

[CP241]

I have a black and decker I bought years ago for like $30. Always worked great.

Have (or had... haven't seen it in a couple years lol) a makita as well. Lots of adjustment ranges for heat but much larger, bulkier, and heavier. More of a pain than its worth

[BlueDubPirate]

May 4, 2019

First, I'll never order anything from Golf Cart King again. The springs I needed were 30.5" and they sent me 28" springs for an EZGo. The shocks I ordered from them are also wrong, they're 2" too short. The point being they don't do a good job of sending the parts that I ordered.




I did get replacement springs but I'm still waiting on shocks. I got about 1.5" of lift and she doesn't sag in the rear anymore. I have wheel spacers on order and once installed, I'll have about 3" of additional width in the wheelbase. I like the new stance.



I pressure washed 11 years of grime from the cart. She is ready for the heart transplant (new motor).






I also installed the new driven clutch which was very interesting. The clutch is 2.5" wider than the old one and 2.5" wider than the shaft it mounts to. I had to fashion a new bolt and keeper to hold the shaft key in place. That took some ingenuity.

[BlueDubPirate]

I mentioned before about having to fix shoddy workmanship. The previous owners did a crappy job of maintaining this over the years. Most notably, nearly all of the bushings were missing! Missing bushings included: leaf spring bushings, swing axle bushing, cargo tilt bushings, and today, I noticed that the stabilizer bar bushings are gone! I'll have to track down some replacements on Monday.

[Fairtax4me]

Yes the cargo box bushings are the same as the spring eye bushings. Sort of nice that club car made them that way, (mostly keeps production costs down).

The sway bar bushings I think you’ll need to get from club car, meaning, Get them from David at Revolution. If your other suspension parts had come from him they would have been right the first time.

What engine are you putting in it that requires that enormous secondary clutch?

[BlueDubPirate]

Originally Posted by Fairtax4me

What engine are you putting in it that requires that enormous secondary clutch?

This little red one: