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Old 05-02-2021, 04:15 PM   #1
bzlytbeer
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Default 1996 Club Car DS - RoyPow Lithium Upgrade

Hey All! Sorry, I was hoping to post this as I was building it, but took a bunch of pics along the way. I got this cart (1996 Club Cart DS Electric) 4 years ago when I bought my house.

It had been used and from what I could tell, the Crown batteries that were in it were made in 2011. It ran pretty decent for the first couple years, then last year, it started dying out very quickly, even after a night of charging. Alas, one sad morning I went to take the cart out, and nothing. 2 of the batteries had finally died and were under 5 volts each. Charger wouldn't even try because they were too low.
I will say though, for those LA batteries to last 10 years is pretty impressive, although, we only use our carts around here half the year.

I had been planning to upgrade to lithium when the batteries died. So...

Battery: RoyPow S51105 48V 105AH
Purchase Date: 3/17/21
Completion Date: 5/1/21

Added the new battery
Painted all black trim
Made the new seats
Added a new steering wheel
Added a new steering assembly
Added a 2nd power reducer
Added a fuse box for all electronics
Added a horn
Added USB ports
Added illuminated rockers
Added a light bar
Changed the old Halogen light bulbs to LED
Added storage compartments and battery cover

















I am extremely pleased with the results, and the performance of the battery so far. I'll update this as often as I can for the next month or so to give some additional information or personal review details.

Thank you to all of you on here - tons of information and some REALLY knowledgable folks - I'm not sure if I would have taken the leap to do this all myself without some of that shared information. The battery swap was fairly easy, just had to make my own bracket. The rest of the wiring was the hard part. I also tried to remove the OBC completely, but got it down to the last 3 wires and not sure what to do with them. One black 10ga to the controller, and a 14ga red and yellow to the solenoid. At least it is bypassed and moved to a better position.

Thanks!
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Old 05-02-2021, 08:38 PM   #2
simicrintz
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Default Re: 1996 Club Car DS - RoyPow Lithium Upgrade

What a great looking cart-well done!!!
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Old 05-03-2021, 12:51 PM   #3
bzlytbeer
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Default Re: 1996 Club Car DS - RoyPow Lithium Upgrade

Quote:
Originally Posted by simicrintz View Post
What a great looking cart-well done!!!
Thank you, Sir! Next winter I am hoping to repair all holes/dings, and paint the body and possibly add a roof.

Oh, and a little more cable management too. It's still a little messy by the FW/RV switch.
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Old 05-03-2021, 09:13 PM   #4
simicrintz
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Default Re: 1996 Club Car DS - RoyPow Lithium Upgrade

Loose ends and tidying up help to keep you out of the clubs (and trouble) at night!
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Old 06-07-2021, 01:51 PM   #5
monstercojones
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Default Re: 1996 Club Car DS - RoyPow Lithium Upgrade

Is it advisable to have the Lithium battery mounted at an angle like that? My install guy said he can't install the RoyPow because the tilt in the chassis would make it unsafe.
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Old 06-07-2021, 02:48 PM   #6
Volt_Ampere
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Default Re: 1996 Club Car DS - RoyPow Lithium Upgrade

Lithium batteries do not care what angle they are mounted at. If they fit, then the angle should be fine.
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Old 06-07-2021, 05:43 PM   #7
DaveTM
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Default Re: 1996 Club Car DS - RoyPow Lithium Upgrade

Quote:
Originally Posted by Volt_Ampere View Post
Lithium batteries do not care what angle they are mounted at. If they fit, then the angle should be fine.
I always thought it was about the angle of the dangle?....Oh ....wait....that's another subject......
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Old 06-09-2021, 03:29 AM   #8
monstercojones
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Default Re: 1996 Club Car DS - RoyPow Lithium Upgrade

Is it ok to mount the lithium on an angle like that?
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Old 06-09-2021, 03:30 AM   #9
monstercojones
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Default Re: 1996 Club Car DS - RoyPow Lithium Upgrade

Quote:
Originally Posted by Volt_Ampere View Post
Lithium batteries do not care what angle they are mounted at. If they fit, then the angle should be fine.
Really? My Installer said he refused to do it at an angle
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Old 06-19-2021, 09:21 AM   #10
HagwoodHunter
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Default Re: 1996 Club Car DS - RoyPow Lithium Upgrade

Where did you find your roypow I'm trying to find a dealer that won't mark it up $500
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