JoshShapaka
№ 001 ★ FLAGSHIPCOMPLETE2020 – 2025 · 2 CHAPTERS
MechanicalMetalworkingElectricalElectronics

1989 Club Car DS Restomod

A clapped1989 Club Car DS, stripped to the frame and swapped out everything electrical but the motor. 36V resistor to 48V solid-state controller with custom wiring throughout. Fabricated new roof structure, bumper, hitch and stereo on top of that.

front bumper and winch, ground level shot
№ 001 — current state
Chapter 01 / 02JUNE 2020

Handed Down

This one wasn't found, it was handed down. My stepfather gave it to me for free; it had been his father's before that, the cart he drove around their land. It arrived in 2020, which made it one of several projects that year that existed mainly because nobody was going anywhere.

Underneath the history it was a 1989 Club Car DS: 36 volts, resistor speed control, the original V-Glide. It had also spent a long time sitting. Parts were missing, the body was damaged, and nothing about it suggested it would be driving again soon. The one thing working in my favor is the thing that makes any old Club Car worth saving — the frame is aluminum. A steel frame would have rotted out years ago and taken the project with it.



1989 Club Car DS Restomod, Handed Down — photo 1 of 13
1989 Club Car DS Restomod, Handed Down — photo 2 of 13
1989 Club Car DS Restomod, Handed Down — photo 3 of 13
1989 Club Car DS Restomod, Handed Down — photo 4 of 13
1989 Club Car DS Restomod, Handed Down — photo 5 of 13
1989 Club Car DS Restomod, Handed Down — photo 6 of 13
1989 Club Car DS Restomod, Handed Down — photo 7 of 13
1989 Club Car DS Restomod, Handed Down — photo 8 of 13
1989 Club Car DS Restomod, Handed Down — photo 9 of 13
1989 Club Car DS Restomod, Handed Down — photo 10 of 13
1989 Club Car DS Restomod, Handed Down — photo 11 of 13
1989 Club Car DS Restomod, Handed Down — photo 12 of 13
1989 Club Car DS Restomod, Handed Down — photo 13 of 13
Chapter 02 / 02

Teardown

Everything came off. I wanted a full inventory of what was still usable, and the frame bare enough to inspect properly. Every part got pulled and sorted into keep or replace. The keep pile came out short. What was left was a clean frame, ready to assess and paint.

№ 001 — the numbers
Finally Completed
Q1 2025
Controller
Alltrax 48V 500amp (SR48500)
Wheels & Tires
14"x7" Madjax Element with 23" Arisun X Trail AT
Battery Cabling
2/0 Welding Lead with Tinned copper Seamless Marine Lugs and Ancor Marine Heatshrink (USA - Flexaprene / Excelene)