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Restoration Early 70's and older restoration projects



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Old 09-18-2022, 10:50 PM   #1
jaret
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Club Car
 
Join Date: Sep 2022
Location: British Columbia
Posts: 11
Default Caroche restoration/update

Hello everyone, I am in need of a bit of guidance on this project that I have acquired.
It is mostly a 1970's Club Car Caroche, except for the rear driveline, someone has gone through the trouble to swap out a Yamaha G2E rear axle, differential and motor. Along with this axle swap the brakes are now cable actuated.

This cart will be used on the course, with a small amount of commuting.
I would like to get rid of the resistor drive system and upgrade to a modern controller. Navitas or Alltrax.

Will the Navitas system work with the Yamaha MT320-06 36V dc motor?

In Canada I can only find the controller in a plug and play kit for the following setups:
Club Car Precedent 2004+
Club Car DS w/ Curtis 1510 or 1515 Controller
Yamaha DRIVE/G29
Yamaha G19/G22
EZGO TXT 36V PDS 2000+ w/1206MX Controller
EZGO TXT 36V DCS 95-99 w/1206 9-Pin Controller
EZGO TXT 36V Non-DCS Series Motor w/1206 5-Pin Controller
EZGO TXT 48V w/ Curtis 1206HB Controller

I realize I will be having to cut up the harness to adapt it to the solenoid and pedal pedal box, but what harness would make the most sense to go with?

Or am I going the wrong way with the Navitas system? Should I be looking at Alltrax?

I do not need excessive speed, just a reliable consistent cart. With the new controller setup I will be changing to 48V.

Thanks for any guidance you can provide, I have attached a few obligatory pictures and will continue to update thought the build.
Attached Images
File Type: jpg Caroche.jpg (197.9 KB, 0 views)
File Type: jpg Yamaha motor.jpg (212.9 KB, 0 views)
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Old 09-19-2022, 06:52 AM   #2
mrmotoguzzi00
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Join Date: Mar 2016
Location: Sarasota, Florida
Posts: 387
Default Re: Caroche restoration/update

Jaret, If Don Plowman doesn't reply here, I would suggest reaching out to him thru the Sponsors Tab at Plowmans Carts. He is the Yamaha Whisper ;)
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Old 09-19-2022, 08:11 AM   #3
jaret
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Location: British Columbia
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Default Re: Caroche restoration/update

Perfect, thanks for the suggestion. I am learning alot the past few days here. I have realized that Navitas offers a AC controller and a DC controller. Now I just need to figure out if I want to convert to AC or stay with DC and if I can make a 10-000686 harness work with my setup.
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Old 09-19-2022, 01:33 PM   #4
Lochlin
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Default Re: Caroche restoration/update

Check with user Scotty B as well. He runs a firm called "Carts Unlimited" and sells a ton of conversion kits / upgrades.
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Old 09-19-2022, 01:49 PM   #5
jaret
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Default Re: Caroche restoration/update

I don't think I have the abilities to pm people with my newer membership.... Is it possible someone could tag these fellows for me?
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Old 09-20-2022, 10:37 AM   #6
jaret
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Default Re: Caroche restoration/update

I got it touch with ScottyB via email and he was unable to help. They don't offer parts for pre 1981 carts and they don't ship internationally unfortunately. Going to try and reach out to Plowman via email here too.

Managed a bit more time last night for the disassembly.
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File Type: jpg 20220919_184821.jpg (262.7 KB, 0 views)
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Old 09-20-2022, 02:38 PM   #7
jaret
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Default Re: Caroche restoration/update

Stumbling through the alltrax website and navitas website I am guessing that this is the setup I am looking for?

10-000782 TSR3.0 600A 36-48V Controller w/ Bluetooth

10-000666 TSX Module Series Motor

Does anyone know if I am correct in thinking I do not need to use the "OBC" in the following diagram?
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File Type: jpg Navitas.jpg (153.4 KB, 0 views)
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Old 09-20-2022, 03:14 PM   #8
Lochlin
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Default Re: Caroche restoration/update

You can disregard the OBC completely. The OBC (on board computer) is a charging component that pairs with Club Car's original charger. Essentially, Club Car's OEM charger was a "dumb" charger that really only consisted of a transformer, relay, and a couple of other rudimentary components. The OBC turned the charger on and off rather than having the charging do it independently. It was a dumb system although I would assume there is logic there somewhere. All the same, you don't need it.
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Old 09-20-2022, 03:23 PM   #9
jaret
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Default Re: Caroche restoration/update

Perfect, thank you.
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Old 09-22-2022, 09:52 PM   #10
jaret
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Posts: 11
Default Re: Caroche restoration/update

A bit more progress the last few nights. Finished tearing down to the bear frame. Started striping the million layers of spray paint, I'm not sure what kind of black magic they used to get it to stick, but it does not want to come off.

Placed an order for the navitas 440amp controller, pb-6 pedal box, 400amp HD solenoid, suspension bushing and tie rod ends.

I would like to go lithium 48v on this, just trying to wrap my head around the bms and charging system on the diy leaf setups. I think the 7 cell pack would be more then enough for a few rounds of golf, and I really like the longevity and low maintenance.

I was looking at the lithium packs on Amazon, but I'm worried about the 1c discharge limit. But maybe it would be fine on a stock motor around the golf course.

I found another surprise. When they swapped the yamaha rear axle assembly in they also utilized the yamaha brake pedal assembly. But they had to fab up a hodgepodge of tubing to get it to work. I'm looking for a used ds pedal assembly or even a precedent gas assembly. Or I might attempt to fab my own.
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File Type: jpg 20220922_192054.jpg (394.8 KB, 0 views)
File Type: jpg 20220922_192101.jpg (407.1 KB, 0 views)
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