Hi Finn, welcome to BGW and thank you for reading through my thread! Converting to solid state is the best thing you can do to an old cart, IMO. What I did was a DIY poor man’s conversion. The reason I say that is because Scottyb at Carts Unlimited (a site sponsor) sells complete kits that include everything you need (see here:
https://www.cartsunlimited.net/unive...rsion-kit.html). I would have gone this route, but I wanted to save some bucks, and I am pretty handy and enjoy fabricating, wiring, etc.
Everything in parts cost me right at $500; here is what all I bought:
-Curtis 1204 controller
-36v Curtis solenoid
-Generic 36v reversing contactor
-Solenoid resistor and diode
-Two reversing contactor diodes
-SPDT switch (for FNR)
-PB-6 potentiometer
-EZGO style key switch
-250 amp main fuse
I didn't need to purchase any cables, as I was able to reuse all of the stock 6 gauge ones.
The most difficult part of the process was mounting the PB-6 pot box to get it to work with the factory accelerator linkage. A couple hours with some scrap metal, a grinder, tape measure, sharpie, and a trip to the hardware store, it was mounted and working like a charm.
The wiring diagram I followed was the one listed in the Curtis 1204 controller manual. I found it to be very straightforward and easy to follow (see pic below).
I did the conversion over the course of three days, working a few hours each day. If you are handy and know how to read a basic wiring diagram, you won't have any trouble at all. The results are what makes it all worth it- silky smooth acceleration with no more of the jerkiness that the stock drive system has.
Start a thread on your cart and post up some pics, I'd love to see it!
