DS with bent frame...what are my options

[Cbehan]

Was in the market for a fixer-upder cart to use around the neighborhood. Bought a 96 CC DS cheap ($400) that needed new batteries. Once the new batteries were in, everything seems to work. Now it was onto making it the way I want it...looking nice and with a rear seat kit.

The cart had a cargo bed on it, and the body could use some TLC, so I took off the bed, and started taking the body off to fill/sand/paint. When I took the back off, I find that rear end is bent...both the I beams are bent about 1" to the passenger side. Also, the rear cross piece that the back of the leaf springs ties into is bent, partially cracked, and the driver-size weld is completely broken off.

Where would you go from here? Should I look to someone to help bend it back in place and re-weld everything, should I just live with it, or should I look for a donor frame?

Thank you all for your time. This place has been an amazing resource for someone brand new into this stuff, it's really an amazing community.

[NoleFan4Ever]

Those frames are extremely easy to weld or repair. I mean hey, its only aluminum right??

The best way to make a quality repair is strip it down to only the frame, place it on a metal work bench or fab table and then bolt it down with dogs or gussets. You can tack weld it to the table but I do not like to do that unless there is no other choice.

Now it is secured so rig you up a come-along or even a chain binder and start pulling it back over in small increments. It will spring a little and that is no problem after you get use to about how much it does with each pull. If needed, you can get a rose bud and heat the area to be bent back, but I seldom have needed that.

Try to use a MIG for all the welds so you get good penetration and the aluminum is filled correctly.

[TahoeDawgZ71]

Club Car used to make a frame repair kit for the DS Electric. When I worked at the dealer we used them all the time. It consisted of a new crossmember and big long flanges that fit on both sides of the I-Beams and bolted on. It was extremely strong (all steel) and very easy to install. I can check tomorrow if it's still available if you'd like.

[Cbehan]

Originally Posted by TahoeDawgZ71

Club Car used to make a frame repair kit for the DS Electric. When I worked at the dealer we used them all the time. It consisted of a new crossmember and big long flanges that fit on both sides of the I-Beams and bolted on. It was extremely strong (all steel) and very easy to install. I can check tomorrow if it's still available if you'd like.

That would be outstanding. I would really appreciate it.

So far, I've managed to flex it back using tow straps, and I've gotten about half of the bend back..but The weld is completely broken on one side, and the cross beam has a bend and a crack in it.

No welding equipment here either, so I'm looking for someone who could do a quick aluminum weld on this to hold it all together once I get it bent roughly back into place.

[BBBHC]

Originally Posted by TahoeDawgZ71

Club Car used to make a frame repair kit for the DS Electric. When I worked at the dealer we used them all the time. It consisted of a new crossmember and big long flanges that fit on both sides of the I-Beams and bolted on. It was extremely strong (all steel) and very easy to install. I can check tomorrow if it's still available if you'd like.

I'd be interested in seeing that too!

I put a "HD" hitch on the other day. That rear stock crossmember looks to me, to need some major bracing.

[TahoeDawgZ71]

Ok I just called and spoke to someone at Club Car who is going to be looking into this for me. I don't believe they're still in production, but there may be some old inventory still there. They're gonna go wipe the dust off of the boxes and see exactly what we're working with here. Standby.

[BBBHC]

Originally Posted by TahoeDawgZ71

Ok I just called and spoke to someone at Club Car who is going to be looking into this for me. I don't believe they're still in production, but there may be some old inventory still there. They're gonna go wipe the dust off of the boxes and see exactly what we're working with here. Standby.

[dundeebarnbuggy]

Originally Posted by BBBHC

I'd be interested in seeing that too!

I put a "HD" hitch on the other day. That rear stock crossmember looks to me, to need some major bracing.

Agree, the stock rear crossmember isn't worth $#%^ for any real towing. my hitch actually supports the rear spreader and holds the frame tails square and in line.

[BBBHC]

Originally Posted by dundeebarnbuggy

Agree, the stock rear crossmember isn't worth $#%^ for any real towing. my hitch actually supports the rear spreader and holds the frame tails square and in line.

dang! That thing looks beefier than what is on my truck!

You by any chance have a couple pictures of it installed?

[Cbehan]

I found a part number Club Car part number 102488801 which is described as a frame repair kit...but it was listed on a random site for $251. I'm interested if that's what David was talking about and what's included in the kit. I think I have a local donor frame I could pick up for less than that, but if it's easier and better long term to stick with my frame and beef up the back end of the cart, then I could go either way.