Star EV carts are trash made with cheap metal. AVOID

[hardhouseinc]

Originally Posted by mikec35

Quite a project you have there, good job keeping at it. Are you going to keep it after you get it back together?

yah this is a long haul project
I wire brushed and did some rust removal primer on the front end axle today

got the wiring 95% figured out and all working
just the fuse box is hankey. They used aluminum not brass or copper and its all cororded. Cleaned it for hours and a couple connections still arent perfect but work. Rewired the rear lights since the pigtails were missing.

I think next or soon I cut out the front end to rebuild it

put the motor back in place after doing a refurb. cleaned the brushes and motor assembly and replaced the bearing. should be good for a few more miles.

Rear of the cart is about done and ready to paint with undercoating
Once the front end is rebuilt and all painted Ill put it back together and hope the motor and controller still work.

[hardhouseinc]

Some updates

[hardhouseinc]

Front end almost done with cancer removal

[hardhouseinc]

getting closer
Painting coming

[dundeebarnbuggy]

Originally Posted by hardhouseinc

Front end almost done with cancer removal

Are those the factory welds in those pics???

[Capt. Lenny]

What I have found is EZGO who makes some of the Star frames powder coat them and moisture gets between the metal and the powder coat and it just accelerates the rust process. If they're parked over dirt for any length of time it makes it even worse. But Club Car aluminum frames have their own problems.

[hardhouseinc]

Originally Posted by dundeebarnbuggy

Are those the factory welds in those pics???

NO
Some asshat tried to FIX stuff
he cut and hacked and did that
he painted over rust

[hardhouseinc]

Originally Posted by Capt. Lenny

What I have found is EZGO who makes some of the Star frames powder coat them and moisture gets between the metal and the powder coat and it just accelerates the rust process. If they're parked over dirt for any length of time it makes it even worse. But Club Car aluminum frames have their own problems.

This frame NEVER had any powder coat
They likely packed the frame and body full of sand and salt
Anything metal on metal or plastic on metal and it just chewed it up

What CC frames have what sort of issues?
I love mine and the aluminum frame seems solid

[hardhouseinc]

Final front end stuff to fabricate and weld in
Rear platform is done..... FINALLY

[hardhouseinc]

lots of small stuff done and ready to bolt on when the frame is done

frame is getting nearly done with fabrication then paint

still need to do the brake cables

still plenty of small stuff to brush down ant paint