I finally have the electrical systems finished, both the Motor Controls and the 12v system.
MOTOR CONTROLS
I started by gutting all of the original wiring, circuits, relays, contactors, ect. Then I put my dream setup together using the best parts I could find. For the motor control system, I installed:
- 72V 105AH Lithium Golf Cart Battery (200A Continuous / 600A Peak)
- Alltrax SR-72500 Motor Controller
- 1500VDC 600A Main Contactor
- Albright SW202 Reversing Contactor
All of this I bolted under the seat. Originally, the car was powered by 48v of lead-acid batteries. The increased voltage and current should allow the car a much faster top speed (55mph instead of 35mph), and more starting torque. The new battery is also a third of the weight of the originals. In addition, I added a battery charger under the seat that connects to the original outside plug for easy charging.
12V SYSTEM
For the 12v system, I installed a 72v to 12v / 10A converter under the hood. I don’t know what this metal bracket was originally used for, but it provided the perfect place to rivet the convertor.
Except for the dash indicator lights, all lights in the car have been upgraded to LED. For the brake lights, I used the original light housings, but I installed LED Modules the I harvested from a set of trailer lights I found at Harbor Freight. For the relay flasher, I used the same robust model of motorcycle flasher relay (Sparck Moto) that I had used previously when I restored my vintage Honda CM400A. I also decided to trade the original electric horn (which drew 10A of current) for a modern motorcycle horn (that only draws 1.5A).
MISC UPGRADES
- The car doesn’t have door locks and there isn’t a glovebox, so there wasn’t a secure storage option. I fixed this by bolting a vintage ammo can to the aluminum plate that used to hold the original contactors behind the passenger seat. Good place to keep a few tools handy.
- I added a USB charger to the dash to keep my phone charged. The one I choose doubles as a voltage meter for the 12v system.
- I recarpeted the car by cutting up an outdoor rug I found at Lowes. I used Aluminum Angle to make side trim.
