DIY Network

Golf-Cart Conversion Kit: Introduction and Prep From "Weekend Mechanic" episode WKM-312

	The 1957 Chevy is one of the most recognizable cars in automotive history and is a genuine American icon.
	The converted golf cart.

In this episode, Weekend Mechanic host Bruce Bonebrake converts an ordinary old golf cart into a mini-replica of a 1957 Chevy Bel Air -- all in just a weekend. In this first segment, he introduces the conversion kit and begins prep work for the project.

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 will be 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. It took us about 12 hours to finish this job. Depending on the nature of the problem, your work time could vary. Allow yourself a full weekend to complete this project properly.

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	Figure A
	Figure B

Introduction and Prep Work

The '57 Chevy is a car that's a true classic with beautiful styling. In this episode, Bruce Bonebrake has some fun with that styling by converting an ordinary golf cart into a replica of the vintage Chevy Bel Air convertible using fiberglass body components (figure A).

In this project, we basically disassemble an old golf-cart body, and replace it with new, professionally painted fiberglass body parts. The components for the conversion come in a kit that includes pre-primed body parts, made specifically for this application, as well as light and electrical components, decals and trim (figure B).

The kit for this conversion cost around $2000, and the fiberglass body parts were professionally pained at a cost of around $500.

Important: Whenever installing fiberglass parts on an existing body, it's advisable to test-fit the parts before having them painted.

• Begin by unbolting the roof, using a 7/16-inch ratchet. After removing the bolts and nuts from the four canopy brackets, carefully lift off the roof (figure C) and set it aside.

• Remove the four bolts holding the front roof-pillars to the body and frame, and lift off the roof pillars (figure D).

• Important: Save all parts removed during disassembly, as you will need some of them later in the project.

  Figure C

  Figure D

  
  

• Remove the center-bolt holding the basket to the back-strap.

• Remove the two bolts that hold the rear roof-pillars (figure E).

• Remove the rear roof-pillars, plastic frame and back-straps (figure F).

• Remove the basket side-bolts and lift off the basket.

• Note: The basket and back-strap can be discarded as they will not be need on the new body which features a trunk. The roof pillars and brackets, however, will be needed on the new body.

  Figure E

  Figure F

  
  

• Unbolt the seat backs (figure G) and remove them.

• Finally, remove the seat bottom in order to gain access to the battery compartment (figure H).

  Figure G

  Figure H

  
  

  Like chrome? This fully restored 1957 Chevy Bel Air has it in spades.

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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