Hello KZfaqrs, a awesome photo and video restoration of my fathers 2002 Club Car "Carry-All" cart. A team effort by us both over the course of about 4 months to complete it and we are very proud of the finished result. As mentioned this is the "Carry-All' cart meaning that it has a tilt bed instead of rear facing seats like most other golf cart style vehicles. The tilt bed can easily carry a load up to 400 or more pounds, and will prove very handy in assisting with chores around the property such as hauling firewood, or a load of soil, etc..Some of the vehicle specifications and upgrades we did are as follows.
The chassis is a "I" beam style constructed out of aluminum as well as the bed, while the other body pieces such as the nose and fenders are made out of a plastic called "Armorflex". The powerplant is a freshly rebuilt Kawasaki 4-cycle, OHV, 351 cc, single-cylinder, air-cooled, pressure-lubricated, engine, with a spin-on oil filter and electronic ingition, making 11.5 horsepower @ 3,600 rpm, we "tweaked" the govenor alittle so these numbers are slightly higher.
The steering is self-adjusting, rack and pinion. The front suspension features independent leaf springs with dual hydraulic shocks, and the rear features leaf springs with dual hydraulic shocks. A 6 inch lift kit was installed to allow for the much larger wheel and tire conbination consisting of 10 inch RHOX Vegas machined aluminum black wheels, wrapped in RHOX Mojave All Terrain- 22x11-10 tires. The brakes are self-adjusting, rear-wheel only, mechanical drum.
The carts electrical system is 12VDC, and with the engine running operates around 15 VDC at 25 amps. The lighting features super LED headlights in a custom fabricated diamond plate pannel, rear facing 5MM LED work lights in a custom fabricated diamond plate pannel as well, red LED rear marker lights, and finally a small LED foot light. These lights are all controlled by independent switches on the dash. Other dash items are a digital fuel level guage with built in hourmeter, voltmeter, low oil level warning light, reverse gear indicator light and a 12 volt accessory outlet. Now you definatly need some tunes while motoring around, this was accomplished with a Panasonic headunit featuring AM/FM radio, CD player, AUX. input for MP3 player, and selectable weather band channels. The radio is protected from the elements with a marine weather resistant cover. The speakers are PYLE 5 1/4 inch with weather resistant drivers ideal for thier mounting location.
Finally, the plastic body parts were re-finished with Krylon "fusion" textured shimmer paint, and the bed received protective "rhino-lined" rubberized finish. All aluminum surfaces were freshened up using a dual action sander, with many custom fabricated diamond plate pannels. A 4 inch black reflective stripe was then applied to the carts sides. To aid in tilt bed dumping and provide a possible future light mounting location a bar was fabricated out of 1 1/2 inch steel tubing and secured to the beds front wall. Lastly, the windshield was created by cutting down a overhead sun shield mounting bar, and fitting it with a fresh piece of 1/4 inch clear lexan.
Thank you to all who have watched this video and have read all of the restoration "story" information on this cart. This was definately a great project with my father and the finished product will be one that will serve him as well as my mother for many years to come around the property.
Please rate, and comment---Thanks again, Enginenut :-)