1992 Club Car DS - Renovation Project

[Engman69]

Also for the front bumper mount plate a little heat and some persuasion should straighten it.

[klanel]

DJGCWB, I did look at your restoration project previously and will refer back to it and others as I go along. Cut all my wiring out this evening and didn't worry about where anything went so I'll definitely be looking for info to rewire the thing.

And Engman69, I hope to pressure wash it tomorrow afternoon. I did scrape off the aluminum battery holders and it may not be as bad as it looks. I've got a couple of migs and one of them I tried to weld aluminum sheet practicing but found it extremely difficult to control. Don't know how the thicker angle would be in comparison.

Had the misfortune of sheering off one of the motor lugs. You can see where it overheated and I guess it caused the nut to sieze. So now, I'll either get it repaired, upgraded by plumquick, or replace. Suggestions anyone?

[Engman69]

Had the misfortune of sheering off one of the motor lugs. You can see where it overheated and I guess it caused the nut to sieze. So now, I'll either get it repaired, upgraded by plumquick, or replace. Suggestions anyone?[/QUOTE]

Don't be afraid to open up the motor and try to replace the terminal. The worst that can happen is u cannot replace it and have to change out the whole motor which is where you are at right now.

[DJGCWB]

Klanel, how's it coming along?

[klanel]

It's coming slowly but surely. Waiting on some parts to get here. Ended up getting a new/used rear end since I lost my patience and destroyed my old differential slamming the axle down. I also have a Bandit on the way and a resistor and diode for the 48 volt conversion.

Still have to get a lift and the only thing I have decided for sure is not to get a spindle lift. So leaning toward a 6" Jakes unless I get some info that persuades me otherwise.

Cut off the front bumper plate and will make a new one. Also plan on fabricating my own brush guard and trailer hitch. Been looking at some factory made ones for inspiration.

Also got my small mig out and practiced my aluminum welding again. Last time I tried was about 6-8 years ago on sheet metal and it didn't work out consistently. But I tried on some thicker stuff and ended up getting some nice welds/penetration. The 11-/2" flat bar that wraps downward for the seat back to screw to had a crack and fell off when I touched it so I will be replacing that and maybe the battery box angles (which actually cleaned up decently)

So here are some photos I took today. Cleaned up battery box, broken flat bar behind seat I will be attempting to replace and weld, painted rear leaf springs, rear shocks, front shocks, brake drums, and cut off bumper. (in no particular order)

[klanel]

Also ordered some aluminum angle and flat bar to replace battery box angles (if I decide), and fix the seat support.

Here's a couple more photos.

[Blitzkrieg]

Looking good dude, keep posting pics of your rebuild

[DJGCWB]

Good progress! Just out of curiosity, why did you cut off the front bumper plate? Just interested in what you're planning on replacing it with.

[klanel]

Originally Posted by DJGCWB

Good progress! Just out of curiosity, why did you cut off the front bumper plate? Just interested in what you're planning on replacing it with.

I cut it off because it was badly bent and it a location where I couldn't hit it from the backside. I'm either going to weld on a new aluminum bumper plate or bolt on a stainless bumper plate but it will be fixed properly when it's finished.

[DJGCWB]

Originally Posted by klanel

I cut it off because it was badly bent and it a location where I couldn't hit it from the backside. I'm either going to weld on a new aluminum bumper plate or bolt on a stainless bumper plate but it will be fixed properly when it's finished.

Gotcha. I remember seeing it all bent up in one of your previous pictures. Good luck man! Lookin good!