Club car brushless conversion.

[eee291]

Spoiler: History

Recently I've been working on various golf carts, converting to lithium, swapping motors and even full brushless conversion.

Saw this thing sitting at a workshop, tracked down the owner and bought it for a friend. The mechanic told me that the batteries were dead and that the brushes from the motor were probably gone as well. I had a new brush set so I thought this would be an easy job...

I opened it up today to find this



The controller is shorted internally as well




Guess it's time for a full lithium/brushless conversion 8)

Update: 26/08/
I've finally made some progress, mounted the motor and controller. More pictures to follow.

 

[j bjork]

Oh shit
Maybe they towed it with a car or something, a lot faster than it is supposed to go?

 

[eee291]

Now that you mention it, it did have a warning triangle on the back and a tow strap on the front
Tow mode also wasn't engaged, so that could definitely have done it.
The guy lives about 10 miles from the workshop, so lots of time to cook it.

 

[fechter]

That's one of the most destroyed motors I've ever seen. Maybe time for an upgrade.

 

[ZeroEm]

Question is the stuff that looks like dirt, really ground up metal?

 

[eee291]

As far as I can tell it's mostly carbon and copper.

 

[Hillhater]

At least the tires are holding air ..! :lol:

 

[eee291]

At least the tires are holding air ..! :lol:

Actually the front right one is flat at least it was cheap

 

[amberwolf]

Looks like it grenaded from overspeed, rather than melting, then all the bits ground each other up really thoroughly...best bet is during the towing--probably was towed at high road speed or even freeway speed, without disconnecting the motor from the wheels, so failure probably occurred shortly after starting out then kept destroying itself the rest of the trip.

Seen a few like that in various conversion threads over the years, mostly on DIYElectricCar forums, often enough from being towed or coasting downhill (but still in-gear) faster than "max design speed"....

 

[eee291]

I've finally made some progress, mounted the motor and controller. More pictures to follow.