DIY Network

Golf-Cart Conversion Kit: Cart Disassembly From "Weekend Mechanic" episode WKM-312

The dash of a restored vintage 1957 Chevy Bel Air.

In this episode of DIY's Weekend Mechanic, host Bruce Bonebrake converts an ordinary old golf-cart into a miniature replica of a 1957 Chevy Bel Air. In this segment, disassembly of the cart continues, stripping the cart down to its bare frame, and some prep work is done for the electrical re-wiring.

Materials:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), some of the specialty tools and materials that needed for this project include fiberglass body panels, custom-covered seats, chrome wheels, new tires, lighting components, body decals, hole-saw, 3/4" driver drill, battery tester, grease gun wire strippers and metal shears. An air-compressor and set of pneumatic tools will is optional, but may be very helpful for this project.

Assisting us with this project is Dennis Ruger of Phat Cat© Carts Inc.

DIY Difficulty Rating for the Project: This job is fun and fairly straightforward, but it does require some careful body work as well as electrical re-wiring and work with batteries. It could be difficult for a new or untrained mechanic. We gave it a difficulty rating of 3 on a 5-point intermediate-level scale.

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	Figure A
	Figure B

Cart Disassembly, continued

• With the seat-bottom removed, the cart's battery compartment can be accessed and the battery cables can be removed.

• Important: Before you begin disconnecting battery cables, make sure the key is turned to OFF.

• Standard golf carts use a fairly complex power set-up with six 6-volt batteries hooked in series. To disconnect the batteries from the cart, there are three connections that must be taken loose: two positive cables and the ground cables. To keep track of the wires and connections, mark each cable being disconnected using tape and a marking pen, then mark the batteries with the corresponding letters (figure A). In this way you can keep track of which cable will need to be reconnected to which battery.

• Once the cables and batteries have been marked, unbolt the battery cables starting with the positive cable (figure B), then the second positive cable and then the ground. It's not necessary, in this procedure, to unhook the cables between each of the batteries.
  

  
  

• Remove the bolts and nuts that hold the seat-brackets to the frame (figure C) and lift off the seat brackets.

  Next, remove the two carriage bolts that hold the bumper to the frame. The bumper and its bolts will not be needed with the new body, so they can be discarded or recycled as scrap.

  With the bumper removed, lift up the golf-bag mats to reveal the screws that hold the body to the rear frame. Remove these screws (figure D).

  Figure C

  Figure D

  
  

  
  

• Remove the seat brackets (figure E), but retain them for use on the new body.

• Remove the transmission controller by taking out the three screws that hold it to the body. Then remove the recharger-cable connector.

• With the last retaining screw that holds the rear body panel in place removed, carefully lift off the rear panel (figure F) and set it aside.

  Figure E

  Figure F

  
  

  
  

• To remove the front body section, you'll need to remove the rubber front bumper to access the bolts that secure the front body panel. Remove those bolts (figure G).

• Remove the T-nuts that fasten the metal edging to the cart. (They are typically located just inside the edging.)

• With the bolts and T-nuts removed, you can lift off the front body-panel (figure H) and set it aside.

  Figure H

  Figure G

  
  

  Figure I

  
  

• Now that the golf-cart has essentially been stripped down to the frame and chassis, you can take it outside and clean it by spraying it down with a hose (figure I). Clean the cart as thoroughly as possible before you begin installing the new parts. The cart frame is made of aluminum, so spraying it with water will not cause rust. You can use an automotive degreaser spray to help with cleanup.

  Important: Be sure that all of the battery caps are on the battery posts before spraying with degreaser.

Important: Included in this segment are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools. Also wear eye protection any time that you are working beneath a vehicle.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

RESOURCES :

Phat Cat® Carts Inc.
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