My 95 DS Build
 

Hey folks, I've been working on a new project here for a month or two now, and having a blast. This was a 1995 Club Car DS that I picked up for a steal, in pretty rough condition. Here it is the day I found it:

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All 6 batteries were shot, and the charger was a pile of parts in the trees.

Got it home, and started stripping it down. This is the first time I worked on a golf cart, so it was a learning experience.

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After cleaning it up, the frame was in pretty good shape, with just some minor corrosion underneath the battery compartment.

Once I got the body peeled off, I sanded it all down and started repairing the dings and scratches using polyester glaze putty. I pretty much followed the instructions posted on this forum for how to repair and paint a golf cart, and it turned out pretty good. I didn't want to spend a whole lot of cash on this project, so I used rattle cans for adhesion promotor, primer, paint and clear coat. I'm happy with the results of my $114 paint job.

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The color in the last picture looks really dull, but the cart was very dusty when I snapped that one.

I painted the factory roof black, along with all the roof and seat supports. I also got a welding buddy to chop 1.5" out of the front supports, to give the roof a slight rake. Made a huge difference in the attitude of the cart, I think!
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I had temporarily recovered the seats with some canvas from my wrecked gazebo, just so I had something to sit on.

For a windshield, I grabbed a chunk of 1/4" plexiglass I had lying around, and tinted it with some Canadian Tire tint leftover from another project. I also painted the factory wheels black when I was bored one night. At this point I was ready to slap in new batteries and test the motor.

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I bought 6 new 8v batteries from US battery to replace the cracked one in the cart. For anyone who complains about the price of batteries, it cost $1140 CAD for that pack, so be glad you live south of the border!

Got some goodies in the mail also!

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Wow nice transformation. How does it run now?

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After installing the new batteries, it took right off. The only issue I have is it really slows down on hills, even with only one person. I'm currently looking for the best deal on a 400 amp controller to try and recover some torque. After that will be a bandit upgrade from plum quick.

Here's how she sits now, with new seat covers and the wheels installed. I got about $2500 invested, and couldn't be happier with the appearance!

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Re: My 95 DS Build
 

That looks fantastic CDK! I've got a 92 DS that i'm just starting out with and the color is exactly the same. May I ask where you got the wheels and seat covers? Do the wheels rub or ride harsh? i'm just getting started on mine, and all i've got done so far is the body. Loving yours, so I'm jus trying to get a good build sheet going so I don't keep changing directions.

Re: My 95 DS Build
 

Are those the seat covers from eBay?
We're they easy to install?