01 48 V CC DS - Hunting Buggy Build ?'s

[Regulator]

Hello - this is my second post and 1st build. I recently purchased an 01 48 Volt Club Car DS with 6 relatively new Trojan batteries. It appears they were replaced in Jan 2015. I will do my best to attach photos correctly. If anyone can help me with the following questions I will be very appreciative.

I plan to build a hunting buggy out of this cart. All suggestions are greatly appreciated. I want to get this right!

1. I think the cart has some sort of lift? However, I plan to purchase a Jakes 6 inch spindle lift. Thoughts?

2. Considering performance, looks, etc - What size wheels and tires would you recommend? I am leaning towards the Swamp Fox tires and 12 inch all black steel wheels with the triangle shaped cut outs. Looking for an aggressive tire. I really like the Dirt Devils but can seem to find them.

3. Recommendation for a 48v to 12v converter. I plan to put an LED light bar, cig lighter for spot light and possibly a winch.

4. Would like to switch all lights to LED. See photo attached. What size and brand LED lights do you recommend. I dont need street legal.

5. I plan to put my Old Towne Canoe on top to carry it down to the lake. Thinking I should weld in some cross beam supports? Is this necessary? May also use the support up high in the front to mount an LED flood. Would you fab up a couple bars to put the canoe on our just lay it on the top and hold it in place with a couple bungee cords? Again not going far or fast.

6. Any tips on painting the body? I plan to light sand and spray with a Rustoleum or Valspar Flat Black paint. I just painted the top. Underside of the top I lightly sanded, then Primed with Bullys then painted flat black with Rustomleum Primer/Paint. On the top side of the top I aggressively sanded primed with Bullys then sprayed with Rustoleum Flat Blk Paint/Primer. Didn't like the look so I repainted with Rustoleum Bed Liner. Figured it would be more durable hitting limbs, canoe rubbing it, etc.

7. Thoughts on creating a quick disconnect between batteries and winch? I am putting front and rear grizzly metal works bumbers with receivers. My plan is to be able to mount the winch so I can take it on and off as needed in either receiver.

8. Do I need to make any upgrades to the controller or motor? Honestly, I picked this up from reading. I have no idea what the controller does and how, if or why I would need to upgrade or change.

9. How much weight would you put in that box? Can I throw a buck on there? Will I need to upgraded the rear springs? Looks like something as already been done to them.

10. If anyone sees any flaws for any of my plans please speak up. You will not hurt my feelings. Just trying to get this right. Also any ideas to make it a better hunting cart.

Thanks in advance for any and all feedback.

IMG_1824.jpg

IMG_1665.jpg

Attachment 141645

IMG_1827.jpg

[NCPW]

[QUOTE=Regulator;1316420]Hello - this is my second post and 1st build. I recently purchased an 01 48 Volt Club Car DS with 6 relatively new Trojan batteries. It appears they were replaced in Jan 2015. I will do my best to attach photos correctly. If anyone can help me with the following questions I will be very appreciative.

I plan to build a hunting buggy out of this cart. All suggestions are greatly appreciated. I want to get this right!

1. I think the cart has some sort of lift? However, I plan to purchase a Jakes 6 inch spindle lift. Thoughts?Do a long travel kit or at the very least an A-Arm lift. The spindle lift will beat you to death off road and tire adjustability is very limited.

2. Considering performance, looks, etc - What size wheels and tires would you recommend? I am leaning towards the Swamp Fox tires and 12 inch all black steel wheels with the triangle shaped cut outs. Looking for an aggressive tire. I really like the Dirt Devils but can seem to find them.Wheel size is your preference, tire size is a better question. I'd go with 22", but 23" at the very most. The larger you go, the more torque you loose and that is precious in a dedicated hunting cart.

3. Recommendation for a 48v to 12v converter. I plan to put an LED light bar, cig lighter for spot light and possibly a winch. I'd use a 30 reducer, but if you want to use a winch you're gonna have to use a dedicated 12V stand alone battery for that. The winch will pull too many amps for a reducer to run it.

4. Would like to switch all lights to LED. See photo attached. What size and brand LED lights do you recommend. I dont need street legal. Any LED kit will be a direct replacement for your cart. I'd suggest making sure the kit is adjustable so you can pattern your beam accordingly.

5. I plan to put my Old Towne Canoe on top to carry it down to the lake. Thinking I should weld in some cross beam supports? Is this necessary? May also use the support up high in the front to mount an LED flood. Would you fab up a couple bars to put the canoe on our just lay it on the top and hold it in place with a couple bungee cords? Again not going far or fast. Don't put too much weight on top, the supports can develop stress fractures from this over time. If only hauling the canoe on top I think that would be fine and I'd only use straps or bungees for that.

6. Any tips on painting the body? I plan to light sand and spray with a Rustoleum or Valspar Flat Black paint. I just painted the top. Underside of the top I lightly sanded, then Primed with Bullys then painted flat black with Rustomleum Primer/Paint. On the top side of the top I aggressively sanded primed with Bullys then sprayed with Rustoleum Flat Blk Paint/Primer. Didn't like the look so I repainted with Rustoleum Bed Liner. Figured it would be more durable hitting limbs, canoe rubbing it, etc. Prep work is the key to good painting. Take your time to sand, fill any bad sport/cracks, prime, paint and clear. Do a search in the design subsection to see the work a lot of members on here have done.

7. Thoughts on creating a quick disconnect between batteries and winch? I am putting front and rear grizzly metal works bumbers with receivers. My plan is to be able to mount the winch so I can take it on and off as needed in either receiver.

8. Do I need to make any upgrades to the controller or motor? Honestly, I picked this up from reading. I have no idea what the controller does and how, if or why I would need to upgrade or change. Depends on the type of terrain you'll be traversing and your budget.

9. How much weight would you put in that box? Can I throw a buck on there? Will I need to upgraded the rear springs? Looks like something as already been done to them. Looks like you already have HD springs, looks like you rear bushing from what I can see could use some replacing to help with any squeaks. I think that box could haul a decent sized deer no problem.

10. If anyone sees any flaws for any of my plans please speak up. You will not hurt my feelings. Just trying to get this right. Also any ideas to make it a better hunting cart.

Thanks in advance for any and all feedback.

QUOTE]

Hopefully others will chime in with the few questions I may not have answered. Good Luck with the build!

[TahoeDawgZ71]

Originally Posted by Regulator

Hello - this is my second post and 1st build. I recently purchased an 01 48 Volt Club Car DS with 6 relatively new Trojan batteries. It appears they were replaced in Jan 2015. I will do my best to attach photos correctly. If anyone can help me with the following questions I will be very appreciative.

I plan to build a hunting buggy out of this cart. All suggestions are greatly appreciated. I want to get this right!

1. I think the cart has some sort of lift? However, I plan to purchase a Jakes 6 inch spindle lift. Thoughts? Your frame has been cut and drop brackets have been installed. I saw it in the picture. Any lift kit that you install on the front of this cart will be extremely tall because you're adding it to an "already lifted" chassis. You'd have to make some straight brackets to replace your Z-brackets in order to bring the frame pieces parallel with each other. Then you could successfully install a new lift kit. I highly recommend a double A-arm lift kit over a spindle kit. There is absolutely no comparison in ride quality, durability, and steering feel.

2. Considering performance, looks, etc - What size wheels and tires would you recommend? I am leaning towards the Swamp Fox tires and 12 inch all black steel wheels with the triangle shaped cut outs. Looking for an aggressive tire. I really like the Dirt Devils but can seem to find them.
Swamp Fox tires are amazing. I have used them on my hunting carts for the past two years.


3. Recommendation for a 48v to 12v converter. I plan to put an LED light bar, cig lighter for spot light and possibly a winch.
Get a 30 amp reducer. It'll power everything except the winch. For the winch, you'll need an external battery to power it with 12 volts. Some people have hooked their winches up to 2 batteries for 16 volts without an issue (myself included), but I'm not going to recommend it to anyone.


4. Would like to switch all lights to LED. See photo attached. What size and brand LED lights do you recommend. I dont need street legal.
I am running into this issue with a customer now. Like you, he has factory headlights in his front cowl. Factory lights are larger than any of the LED lights that I have access to. They simply won't fit because the opening is too large

5. I plan to put my Old Towne Canoe on top to carry it down to the lake. Thinking I should weld in some cross beam supports? Is this necessary? May also use the support up high in the front to mount an LED flood. Would you fab up a couple bars to put the canoe on our just lay it on the top and hold it in place with a couple bungee cords? Again not going far or fast.
I recommend adding some sort of support. I'm not sure what a canoe weighs, but the windshield frame isn't built to hold much weight.


6. Any tips on painting the body? I plan to light sand and spray with a Rustoleum or Valspar Flat Black paint. I just painted the top. Underside of the top I lightly sanded, then Primed with Bullys then painted flat black with Rustomleum Primer/Paint. On the top side of the top I aggressively sanded primed with Bullys then sprayed with Rustoleum Flat Blk Paint/Primer. Didn't like the look so I repainted with Rustoleum Bed Liner. Figured it would be more durable hitting limbs, canoe rubbing it, etc.
Can't help here. I take all of my custom builds to a paint and body shop and let them handle the paint work


7. Thoughts on creating a quick disconnect between batteries and winch? I am putting front and rear grizzly metal works bumbers with receivers. My plan is to be able to mount the winch so I can take it on and off as needed in either receiver.Good idea. Lots of people do this.

8. Do I need to make any upgrades to the controller or motor? Honestly, I picked this up from reading. I have no idea what the controller does and how, if or why I would need to upgrade or change.
The controller disperses power to the motor. The controller in your photo is a Curtis 225 amp IQ controller. The IQ system came out in 2002. I noticed you said your cart was an 01. Post the serial number for the cart. I have my doubts about it being an 01. An upgraded controller would provide more amperage and give you more power. Common upgrades for hunting carts consist of a heavy duty solenoid, heavy duty cables, a high torque motor, and a 500 amp controller

9. How much weight would you put in that box? Can I throw a buck on there? Will I need to upgraded the rear springs? Looks like something as already been done to them.
It already has HD Springs on it. Standard leaf springs are mono-leaf. As for the box bed, it looks to be sturdy enough to throw a buck in.


10. If anyone sees any flaws for any of my plans please speak up. You will not hurt my feelings. Just trying to get this right. Also any ideas to make it a better hunting cart.



Thanks in advance for any and all feedback.

Attachment 141643

Attachment 141644

Attachment 141645

Attachment 141646

I've answered these questions for you.

[Regulator]

Wow. Thanks for all the advice fellows.

1. What type of A-Arm lift do you recommend? What the heck am I getting myself into with regards to install. Sounds like some changes have already been made to this cart.

[TahoeDawgZ71]

Originally Posted by Regulator

Wow. Thanks for all the advice fellows.

1. What type of A-Arm lift do you recommend? What the heck am I getting myself into with regards to install. Sounds like some changes have already been made to this cart.

I use the All-Sports Super Sport lift kits for DS carts. It's top quality. But first, you're going to have to figure out how to remove that Z-bar lift kit. The frame was cut in order to install it. You're gonna have to fabricate some straight steel plates or just live with what you got. Unless you want a 10 inch lift that is...

[Regulator]

Oh boy. Sounds like I have some work ahead of me.

Can anyone provide me ideas and more detail on how to solve this problem?

Could I buy a 3 or 4 inch lift versus a 6? Or do I need to fabricate something to correct was has been done to this cart?

[jakesnake27]

If it were my cart, I would get some plates of steel and bolt the frame back the way it was. Then I'd install a 6" double a-arm lift. As someone mentioned, those u-bolts in the rear don't look right, the tops of those bolts are rounded, made to go around the axle tube, but those need to be squared, as they sit on top of the leaf springs. The best way to install a rear lift is well documented here: http://www.buggiesgonewild.com/elect...stall-way.html

One other thing, I'm curious about your motor. It looks like it may have been upgraded. Can you get a close up pic of it?

[TahoeDawgZ71]

Originally Posted by Regulator

Oh boy. Sounds like I have some work ahead of me.

Can anyone provide me ideas and more detail on how to solve this problem?

Could I buy a 3 or 4 inch lift versus a 6? Or do I need to fabricate something to correct was has been done to this cart?

You're going to have to determine how big to make the plate. Yes you'll have to fabricate them yourself. I've attached a photo that shows an un-cut frame and gives a measurement to use as a reference. You could use a 3 inch lift in conjunction with your existing lift, but your front tires are going to stick out of the front of the cart pretty far. The lift on your cart now lengthens the wheelbase, as does the double A arm lift kit. It would look kind of funny and I'm not crazy about that aftermarket Z-bar lift. If it was the factory lift kit I'd be more willing to tell you to combine the lift kits, but with it being aftermarket I'm not fond of the idea. The factory kit uses 4 plates 1/4" thick, and actually sandwiches the frame on both sides. Your kit only bolts up to the outside of the frame beam and it's not as strong. I've also seen those kits break in the past. Make 4 steel plates and get factory geometry and buy a 6" lift. You'll be glad you did.

[Regulator]

I would like to thank everyone for all the help. Especially Dave at Revolution Golf Cars. I started this project back in Sept and honestly it was a much bigger project than I was expecting. I took my time and it has been a lot of fun. I learned a ton and already thinking about building another for my wife to take to our beach house. At first she could care less about what I was doing. Now she wants hers for the beach. Maybe that will be next winters project.

I can't thank Dave enough for his patience and knowledge. Dave answers his phone on the 1st ring and took the time to answer all of my questions. This project was sooooo much easier because of Dave. He literally walked me step by step. The cart is done! I will start to post photos of each step with details as to what I had to do. I literally tore this thing down to the frame and put it back together. Hopefully it will help someone else in the future. Not going to be abled to post all the photos and steps tonight.

[larrybi]

Regulator...I have just completed my hunting cart and have some pics you may find interesting if I can get them uploaded. I used Grizzly brush guard on the front of mine and made a winch mount for it also I run a separate battery in the bagwell for the winch and the led lights. The lights mount on the brush bar and are 3" square and have 6 led's in each light (18 watts) I run 23" tires and have a six inch spindle lift.