Project... Dumpster Fire? Crispy Cart? Burnt Up to Turn't Up?

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iamdub

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Couldn't settle on any one name for this project, so y'all give me your opinions.

Anyway, I stumbled onto what I thought was a deal. At least, it seemed that way at first, but it still may be. Too late to back out now, though.

Story time: I've been letting my 12-year-old practice driving. We take mom's car to the community center parking lot, I set out some cones, and we have some fun. We live in a very rural area and four-wheelers, SXSs and golf carts are always cruising around. I've always wanted a side-by-side ("SXS") to tool around on and use for yard duties but a golf cart is more in my budget. Now that Kin's "driving", I'm more prompted to get something going. I had planned to pull the old Club Car gasser out of storage and get it going. In addition to swapping in a 13HP I have on hand, I wanted to either lift it or lower it. After I ran across a pretty good deal on some nearly-new 23" off-road tires on 12" steel wheels, my decision was made to lift it. I found the wheels and tires while on a job two hours away from home. The guy runs a small golf cart business out of his home and had a 48V '07 Club Car Precedent tucked away on his property. It needed some *ahem* "TLC" and he seemed unsure of what he was gonna do with it and showed it to me as more of a conversation piece than an attempt to sell it. I never had any real interest in buying another cart so I didn't really inspect it. I paid him for the wheels and tires and hit the road. After really looking at the gasser in storage, I decided I'd probably get an electric cart going much sooner and probably cheaper, so I called the guy back to discuss making a deal. He told me "It's yours for $300. The motor alone is worth that, probably more". Knowing it had a 6" Madjax lift and a pair of Rigid Industries 3" cube lights, I decided it was definitely worth more than $300 if I ended up parting it out. He said he had a charger for $200 and three good used Trojan batteries in another cart he'd let me have for $75 each. They're around $200 each new, so that was a good enough price for me! I hitched up my 5'x8' and drove the two hours to his place last Sunday morning. After we got everything loaded, he said "Okay, we're at 300 for the cart and 200 for the charger. I'll do 100 for the batteries". I thought he raised his price on the batteries to $100 each instead of $75 each. He meant $100 for all three! I couldn't Venmo him quickly enough! We shook on the deal and I took off, proudly dragging my new toy behind me.


Now for the pics!

Home safe:

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That RealTree wrap has got to go!

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It looks goofy with a lift on stock wheels and tires:

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Among the extras is this flip-flop seat/bed. These are around $250. As a seat:

IMG_3535.JPG


...And as a bed:

IMG_3536.JPG
 
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iamdub

iamdub

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The aforementioned Rigid LED cube lights. These are around $150/pair:

IMG_3532.JPG


...And Madjax 6" lift, a ~$400 item:

IMG_3542.JPG



Oh, it also has a lightly tinted foldable windshield. These are around $50-$150, depending on brand. For a cart with $850 in add-ons, I'm satisfied with my $300 investment!
 
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iamdub

iamdub

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Now for the big, hairy "but" and reason behind the title:

I got it for $300 because it needs work. The guy got it from the original owner because he had an accident. He replaced a battery and his kids went for a ride. Soon after they parked in the garage, it caught fire. It turned out the guy didn't tighten the battery cables.

On the outside, it looks like it just needs to be pressure washed. The whole scene changes once you flip up the seat:

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The controller may be okay. I'd really like to get an upgraded one, but I'm gonna try this one just to get it going:

IMG_3538.JPG


The solenoid looks okay as well. I'm wondering if the original owner replaced it when he replaced that battery. The factory solenoid is in the dash storage cubby. This one may be an upgraded one, I haven't ID'ed it yet:

IMG_3539.JPG



I don't know what this piece is, but it looks fine:

IMG_3540.JPG
 
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iamdub

iamdub

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The (mostly) unburnt batteries on the other side look like they just need to be cleaned off and have the caps replaced. First step was to remove all the batteries. I'm glad I checked the burnt ones- they were still hot with 12.xx volts each, exposed plates, acid and all!

IMG_3545.JPG


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I removed the good batteries with a handle I made from a length of rope and "S" hooks from a rubber bungee. I extracted the burnt ones by grabbing the broken terminal with Vise Grips and hooking the other terminal with a claw hammer:
IMG_3548.JPG



Waste of a good battery. The other two are Trojan 1275s, as well as the three extras I bought:
IMG_3549.JPG




Conveniently enough, we have our annual hazardous materials collection day this Saturday. So I'll be able to offload these batteries, some tires and some broken TVs I've been anxious to get rid of.
 

07Burb

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Wow....was a good deal but the work it needs seems daunting. That’s crazy
 

Tonyrodz

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The (mostly) unburnt batteries on the other side look like they just need to be cleaned off and have the caps replaced. First step was to remove all the batteries. I'm glad I checked the burnt ones- they were still hot with 12.xx volts each, exposed plates, acid and all!

View attachment 261171

View attachment 261172


I removed the good batteries with a handle I made from a length of rope and "S" hooks from a rubber bungee. I extracted the burnt ones by grabbing the broken terminal with Vise Grips and hooking the other terminal with a claw hammer:
View attachment 261173


Waste of a good battery. The other two are Trojan 1275s, as well as the three extras I bought:
View attachment 261174



Conveniently enough, we have our annual hazardous materials collection day this Saturday. So I'll be able to offload these batteries, some tires and some broken TVs I've been anxious to get rid of.
Watch yo' ass! Acid sux!
 
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iamdub

iamdub

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Wow....was a good deal but the work it needs seems daunting. That’s crazy

It does at first glance! But, I don't think it's all that bad. The body, seat and plastic bucket that the batteries sit in are all easily replaced. So is the wire harness. With the body, bucket and harness yanked, all of the fire damage can literally be "unbolted" and disposed of, leaving a clean aluminum frame to simply bolt on the replacement body, harness, etc. There are a few cart places around me that have small salvage yards I can dig through. Trying to get to one today or tomorrow.
 
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iamdub

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Found a cart salvage yard about 30 mins from me. Scored a good rear body section for $100 and main wire harness for $50. I found after they pulled the harness that a rat had chewed a small section of the wiring. I'll just splice in sections from my existing harness to keep the colors and gauge sizes matching. Considering a new harness is $360+, I'm happy to do the extra work. Although it's technically a separate harness, the motor power harness was attached to it with a zip-tie, so they included it, making it an even greater deal.

I think there's another small harness for the accessories and maybe the brake lights I still need to get. I'll sort it out once I start dismantling the charred stuff. Those harnesses are cheap, like $30-$50. The last big piece I need is the battery bucket. I'm gonna search some other places for a good used one. If I strike out, the local Club Car authorized dealer said they'll order me one and it'll just be the cost of the part ($110.xx) since it'll ship along with their other freight.
 
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08grey

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That’s a cool end of summer project


Sent from my iPad using Tapatalk
 
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iamdub

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Made some nice (and quick) progress last night.

Here's how I started, viewed from the left:

IMG_3614.JPG



...and from the right:

IMG_3615.JPG



I removed all the wiring and used my new-to-me recip saw to cut the bulk of the body to break it free from the molten battery bucket, then removed the bucket. This is what I'm left with:

IMG_3634.JPG



In all of this, I realized that I actually didn't need that main harness. There's only a few wires with mild-moderate burn damage and it's only on the last ~4". I can easily splice on new wire, terminals and replace the loom and it'd be 100%. Since the replacement harness I got yesterday needs splicing in the middle of it, repairing the original harness would be easier. I wish I had known it wasn't so bad so I could've saved a few bucks on that other harness. But, I wanted to have the replacement in hand for reference since I thought the original was destroyed. It was mostly just covered in melted battery bucket plastic that peeled and flaked right off. The harness that got the most damage was the power cables to the motor. I got this harness as well yesterday, so that's handled. Although, I'll probably remake it with larger gauge cables since I'll be making upgraded battery cables.


While inside the cart, I noticed this label:

IMG_3633.JPG



I filled out the questionnaire on the company's site to get the details on it- Modded for torque? Speed? Both? Either way, this was an exciting little bonus to find.



I'll have to remove the flip-flop seat to remove the remains of the body (those two rear fender/side pieces). The only remnants of the fire damage will be that back lateral span. It'll be covered by the new body and battery bucket, so I'm not messing with it. I'll scrub it to get the stinky soot/molten plastic smell off when I spray down the cart.
 
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iamdub

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EMP emailed me back:

"This motor was sold March 2016 to Top Carts 413 for this application: 48V Club Car IQ lifted with 23" tires, 4 passenger, stock IQ control Curtis 1515 or 1510, wants some speed ~19MPH flat ground for NEV use."

I guess this means the motor was built for speed rather than torque. I hope the torque wasn't reduced any or much. It's flat where I'll be driving it with the biggest slope being the ramp on my trailer when transporting the cart. I would like to be able to drag a small garden trailer for yard chores, though.
 
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iamdub

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That new battery bucket the dealer quoted me was actually for the '08+ Precedent, which has a six 8 volt battery configuration. I went back to the cart scrap yard yesterday to bring a load of batteries to recycle and to make a deal on the used bucket. He was still kinda firm on his original $100 quote even after I told him the new one was $120 after tax. He knew that (1) I didn't wanna wait 2+ weeks for it to come in and (2) I really didn't wanna cut the bottom out of my existing one to drop inside the new one to change the battery configuration to four 12 volt batteries. He offered me $30 for my load of batteries, which was about what I was expecting (I was just glad to get rid of them all), so I got the bucket for $70. One side has a large chunk busted out, but that side on my original bucket is good. I'll cut out the broken section with straight and square cuts, then splice in the good section from my original one using JB Weld Plastic Bonder. Just extra work I didn't wanna have to do, but these buckets pretty much only exist in scrap yards. If any new ones are around, they're buried and forgotten about in some cart part's storage. I'm fortunate to have found this one just 30 minutes from me. Getting back to work...
 

Rocket Man

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Nice little project. It’s always kind of cool to keep removing stuff until you get to the point of where you feel comfortable to start the rebuild. Like you said, it doesn’t always have to be back to the parts that have zero damage. Looking forward to more progress.
 

Dpayne

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There is your problem. Says it right there US Battery. Lost 4 custom carts at once all burned to the ground and half of our house at 3am. All the carts had new US Battery 8 volts. Fire marshals determined that the batteries in on the carts was the cause. Not plugged in or anything. Just sitting in the driveway with for sale signs on them.
 
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iamdub

iamdub

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Nice little project. It’s always kind of cool to keep removing stuff until you get to the point of where you feel comfortable to start the rebuild. Like you said, it doesn’t always have to be back to the parts that have zero damage. Looking forward to more progress.

Yaaaaas! It was literally like unbolting the fire damage and removing it in pieces.
 

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