2001 Club Car DS Hunting Buggy Build
 

Got my 2001 Club Car DS ready for the upgrades. Picked this up in OH last week. Has all factory gear, runs and drives great, but need to beef this thing up to go offroad. Thanks to all the forum sponsors/members for all their help thus far (gonna need more as I get going).

Have my D&D 4:2A high torque motor, Alltrax 48500 controller, 500amp HD solenoid, and the HD F/R switch. Also grabbed the upgraded wire kit to handle the new power plant.

Batteries are a couple years old and are showing good voltage, so keeping those for now and maybe do a lithium upgrade down the road.

Got the Allsports 6" A arm lift, HD rear springs, 23" tires w/10"wheels. Front brush guard, front basket, carbon fiber dash, in dash volt meter, wiring harnesses for LED light bar/spot lights, voltage reducer, black diamond rocker panels, Rear seat/cargo box, new steering wheel, and a few other odds and ends.

The only thing I haven't gotten is the camo spartan body. Debating on getting that or having the factory body hydro dipped.

Anyway, hopefully will get the body removed this weekend and hopefully start the engine/controller/solenoid/FR switch installed. Figured since I need to pretty much disconnect the rear axle for the HD leaf springs, might as well change out the motor while I have it down.

Re: 2001 Club Car DS Hunting Buggy Build
 

Looks like you are going to have a very nice cart!

Post lots of photos so we can follow your build.

Where are you located?

Re: 2001 Club Car DS Hunting Buggy Build
 

I plan on taking lots of photos during the upgrades. I'm sure I'm gonna have to ask for lots of advice from the experts on here!

I'm just north of Pittsburgh.

Re: 2001 Club Car DS Hunting Buggy Build
 

Where did you get the black diamond rocker panels?

Re: 2001 Club Car DS Hunting Buggy Build
 

ecartparts.com

He had Allsports I believe make them for me. Don't quote me on who did it, but call/text him, he will let you know.

Re: 2001 Club Car DS Hunting Buggy Build
 

So yesterday, decided to remove the body from the DS. Wasn't too hard of a process. Some of the screws/bolts were old and seized up, so need to replace a few of those. Once the body came off, wanted to remove the batteries and clean them up and get the battery tray cleaned up. There was some corrosion on a few of the battery terminals and some corrosion on some areas of the battery tray. Got some spray from the auto store to see if I could get the corrosion cleaned off and assess the condition of the battery tray. So far, I think there may only be one support that needs replaced. Once I finish cleaning it up completely, I'll know more.

Re: 2001 Club Car DS Hunting Buggy Build
 

Flip it on its side and you wont have to crawl under it. :mrgreen:

Re: 2001 Club Car DS Hunting Buggy Build
 

So after cleaning up the battery tray, I think I may go ahead and replace all the supports and even add one across the middle of each tray. I bought my 1/8" by 1.5" aluminum angles. It looks like someone already replaced the inner support on the passenger side. There are bolts holding this piece in place instead of welds. The rear corner of this support has broken away anyways. Gonna weld in all new battery supports and be done with it since I have it all torn down anyway, never gonna have this amount of access again.

Re: 2001 Club Car DS Hunting Buggy Build
 

Great idea I may do this when I redo my wiring!

Re: 2001 Club Car DS Hunting Buggy Build
 

Found a guy up near me that will hydro dip the body and roof for me.

While waiting I'm gonna finally swap the motor/controller/F&R switch/Solenoid.

Want to trace out the wiring on the cart and get rid of the excess stuff that I don't need and just clean it up a bit.

Have been looking at the Jake's Sport Shifter and the Allsports shifter. The Jake's shifter says it is only for gas models, however I talked with a guy that used it on his electric cart and said it worked just fine with no modifications.