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Old 08-31-2018, 12:31 PM   #1
NCPW
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Join Date: Sep 2015
Location: North Carolina
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Default Club Car DS lithium upgrade and 4-Link

This will be a VERY slow build compared to the ones I read here daily. Hope to have it finished up within a few weeks but I'm not in a rush and not on a timeline so I plan on doing it right the first time...hopefully. Plus I plan on buttoning up a few things like wiring to make it more aesthetically pleasing, cleaning/painting the frame again and few other things.

I upgraded the cart a couple of years ago from a 36V resistor cart to a solid state drive system and 48V as well as some cosmetics more suited towards hunting and running through the woods (which is what the cart does most of the time). So this will be Ver. 2.0 when I'm done.

First thing on the list is gathering everything needed to do a lithium conversion. I've been reading/studying on converting to lithium since reading through SportCoupe's http://www.buggiesgonewild.com/elect...txt-build.html a few years ago, not to mention every other lithium build the great members here have posted since. I have learned a great deal from a lot of you and asked my questions via PMs, e-mails and phone conversations. So thank you to those members and one in particular who has been a great asset to me and this forum is very lucky to have him as a member. He knows who he is and I won't mention his name because I don't want him to get bombarded with questions but if he chooses to speak up, that's his decision.

Second thing is ditching the HD rear leaf springs for a better ride using a 4-link set up. I've read though countless threads on here as well as off-roading forums and watched many youtube videos (makes me a professional now, right? ) to decide I want to go with a triangulated set-up. I think this will make it as easy as possible, avoid having to use a panhard bar and get around/clear the motor without issue hopefully. I'm not going for extreme articulation but for a more comfortable ride.

For the lithium conversion I have everything in my possession right now except the BMS and display from Zeva. They were out of stock when I ordered earlier this month but Ian expected to be able to ship my order out anytime between now to the beginning of September. In the meantime I'll do what I can with what I have. For the 4-link I have all my tubes, hiems, spacers, jam nuts, shock mount tabs, angle steel to mount everything, wheel spacers and coilovers.

After removing all current electronics and taking many pictures to make sure I wire everything back up correctly.
BateryTrayBefore.jpg

Here I cut out and ground down the necessary aluminum angle to get the diamond plate to fit nicely. This is a dry fit and nothing is secured down yet because I plan on sanding and painting first.
BatteryTrayAfter.jpg

More to follow
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