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Old 03-17-2017, 09:03 AM   #1
saladsack
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Default 1999 Club Car DS body cracked

There a large crack in my golf carts body above the front bumper. How can I fix this?







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Old 03-17-2017, 11:29 AM   #2
NCPW
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Default Re: 1999 Club Car DS body cracked

Looks like some good separation you have there. I'd look for a used front cowl to replace it with before putting in the time/effort to glass it and repaint. DS body parts are pretty easy to find and reasonably priced.
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Old 03-17-2017, 11:30 AM   #3
saladsack
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Default Re: 1999 Club Car DS body cracked

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Originally Posted by NCPW View Post
Looks like some good separation you have there. I'd look for a used front cowl to replace it with before putting in the time/effort to glass it and repaint. DS body parts are pretty easy to find and reasonably priced.


The problem is the custom paint job


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Old 03-17-2017, 12:36 PM   #4
cruisinkruty
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Default Re: 1999 Club Car DS body cracked

Replace,nothing will hold that secuely unless you remove and patch from behind with plastic resin
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Old 03-17-2017, 12:39 PM   #5
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Default Re: 1999 Club Car DS body cracked

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Originally Posted by saladsack View Post
The problem is the custom paint job


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Can't tell from the pics, but what do you mean custom? I just don't think patching that crack will be worth it to you.
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Old 03-17-2017, 01:17 PM   #6
saladsack
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Default Re: 1999 Club Car DS body cracked

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Can't tell from the pics, but what do you mean custom? I just don't think patching that crack will be worth it to you.

It's a one if a kind color. I can't buy a replacement part that will match.


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Old 03-17-2017, 01:41 PM   #7
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Default Re: 1999 Club Car DS body cracked

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Originally Posted by saladsack View Post
It's a one if a kind color. I can't buy a replacement part that will match.


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get a replacement cowl and paint it to match your back ... you will have to paint a fix anyway
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Old 03-17-2017, 04:12 PM   #8
55BigBlock
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Default Re: 1999 Club Car DS body cracked

The DS body is made of a material they call "Armorflex". It is a polycarbonate. There is no adhesive I've found that will fuse to this material. I've tried epoxies, cyanoacrylates (super glue), panel adhesives, and hot melt adhesives to no avail. Some seem to stick, but all succumbed to moderate pressure. The only thing you can do is use a soldering iron or some other type plastic welder and try to "stitch" it together from the back side. If you take your time and try to reinforce it with some donor material you might get by. I'd look at a new complete replacement body. They are very reasonable and the color is molded through.
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Old 03-17-2017, 06:18 PM   #9
DannyAbear
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Default Re: 1999 Club Car DS body cracked

Polycarbonate is like lexan, it doesn't crack and split, a good glass warehouse will have a cement to adhere it together, I've built a couple of aquariums doing this. It's my understanding the front is ABS plastic, like black drainage pipe and fittings, it is also weldable, a plastics shop should be able to weld it up, or I think Harbor freight sells a cheap plastic welder, the abs welding rod may be harder to procure
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Old 03-17-2017, 09:29 PM   #10
lockman1
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Default Re: 1999 Club Car DS body cracked

It looks like it took a pretty good impact to dent the bumper and crack the cowl like that,
I'd also look for broken welds, and bent parts underneath also!

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