My Club Car DS Conversion

[GBLGBL]

Hello all, this is my first time doing anything to a golf cart so I wanted to share/pass on my experience so far. First and foremost, IT'S A BLAST, once of course you begin to understand how things work. Probably would have not been able to get to this point without the help of ScottyB and this GREAT forum.
Moving on to the "nuts & bolts" of things. This is work done on a 2002 Club Car DS 36V Vglide which I quickly found is outdated and not going to work for my needs. A few quick emails to ScottyB and the C54 Version 2 kit was on the way.
Started out gutting the entire battery compartment including all of the "toaster oven" system. Cleaned everything with battery cleaner first, followed by a strong(not safe for coated wheels) aluminum cleaner. Had to replace a few of the battery rails with new 1 1/2 X 1/8 aluminum angle stock. Then sprayed compartment with a spray on bed liner. Installed new AllTrax Controller & HD solenoid per location instructions given by ScottyB.

[GBLGBL]

Next, I moved onto installing new HD F&R switch and electric pedal. At first, the electric pedal appeared to be a huge obstacle, since my OE pedal configuration was nothing like what was pictured in the instructions which appear to be pre 97 Club Car. A few emails to ScottyB a night to sleep on, and I was back on track. All that needs to be done here is to remove the OE GO pedal and leave all the existing Go pedal linkage as well as existing brake pedal linkage since these are interconnected. Also had to shift mounting the new electric pedal a bit to the right to get a firm mounting surface - whole in floor panel where original Go pedal would not allow for this.

[GBLGBL]

Underneath cart showing electric pedal mounting with supplied mounting plate

[GBLGBL]

Next, moved onto the wiring phase both small gauge & new 2G cables supplied by ScottyB. I hated all the wires that crossed over the top of the batteries on the old system so I basically created wiring harness for all the new small gauge wiring and found a way to mount all the 2G cables so that everything was streamed lined.

[GBLGBL]

Another view of small gauge wiring....

[GBLGBL]

Been working on some other things this week like brakes & front hub bearings so hopefully I will get some time later in the week to go get all new batteries and fire this thing up.
Hopefully, this might help some who might be considering doing this or already in the process. It really is a simple process and even made so much more by ScottyB's detailed instructions.
Thanks again ScottyB for all your help and again to all the forum members who share their knowledge here.

[Aflyer]

GBLGBL,
Nice work, I like your equipment choices and your neat and orderly installation.
Aflyer

[Kashmir]

I'm pretty sure the XCT controllers are resistant....
I might be wrong, soctty?

[scottyb]

The Alltrax Control is rated water resistant.
It has been proven water proof by one BGW member.
Most all of the cart components including the reducer we sell are splash resistant. This means they can handle the incidental splash or over spray from cart cleaning. A shield or diverter is a good idea.

[GBLGBL]

OK got my battery pack installed with all the heavy wiring. Now test time....
Forward, everything seems to work just fine, however in reverse nothing. No solenoid click. Also, what seems not right is that even in forward, controller has no light up. In other words, I have no LED status for anything. Anyone have any suggestions?