Glen Batchelor
Active Member
I just finished my pool buggy project and thought I would share some pics and offer Q&A on the process.
This 2000 TXT was street rebuilt by Bills Carts in 2005. I picked it up off Craigslist for $150.
Still trying to get the VIN sticker. The VIN tag cleaned up nicely with the wire wheel.
It spent most of the time in Ocean Isle Beach apparently, based on the sand in the motor and overall salt corrosion.
The motor end housing was busted and was not reparable. Replaced with an AMD fleet speed.
The differential looked brand new when I cracked the cover off to inspect. The axles and gearing was in perfect condition. Same for the steering rack and pinion assembly. I got lucky!
The throttle box was full of water at one point. The ITS was split open and rotted, the split nuts had dissolved into rust stains and the micro switch had no terminals. Had to rebuild the entire throttle assembly.
Alltrax DCX400 controller and solenoid was functional and retained. Working on offering replacement PDS adapters for the DCX controllers. The original one has rotted terminals. The replacement adapter from Alltrax is $80 for less than $20 worth of parts.
1 of the 6 batteries was salvageable. Most of the expense ended up being the batteries. I tried desulfating them for almost a month to no avail.
The driver side leaf spring perch fell off when I cut the bolts. The OE weld was completely gone and there was hardly any meat to it from the factory. Both sides were rewelded.
Lots of sanding, grinding, welding, rewiring, sawzall blades and painting. It took me right at 2 months to cut it up, clean the rot and rebuild. The frame sections were pretty solid.
New corner and side lights all around, reverse LED drive light, LED dome light, USB charger, LED charge level, custom ball holder plate, rebuilt throttle assembly, wheels and tires, brake cables and equalizer, brake assemblies, front spindle bearings, tie rods, front roof support, motor, mounting hardware front springs, heavy duty rear springs, hangers, bushings, shocks, 5 batteries, paint, turn signal assembly, steering column cover and mirror.
This 2000 TXT was street rebuilt by Bills Carts in 2005. I picked it up off Craigslist for $150.
Still trying to get the VIN sticker. The VIN tag cleaned up nicely with the wire wheel.
It spent most of the time in Ocean Isle Beach apparently, based on the sand in the motor and overall salt corrosion.
The motor end housing was busted and was not reparable. Replaced with an AMD fleet speed.
The differential looked brand new when I cracked the cover off to inspect. The axles and gearing was in perfect condition. Same for the steering rack and pinion assembly. I got lucky!
The throttle box was full of water at one point. The ITS was split open and rotted, the split nuts had dissolved into rust stains and the micro switch had no terminals. Had to rebuild the entire throttle assembly.
Alltrax DCX400 controller and solenoid was functional and retained. Working on offering replacement PDS adapters for the DCX controllers. The original one has rotted terminals. The replacement adapter from Alltrax is $80 for less than $20 worth of parts.
1 of the 6 batteries was salvageable. Most of the expense ended up being the batteries. I tried desulfating them for almost a month to no avail.
The driver side leaf spring perch fell off when I cut the bolts. The OE weld was completely gone and there was hardly any meat to it from the factory. Both sides were rewelded.
Lots of sanding, grinding, welding, rewiring, sawzall blades and painting. It took me right at 2 months to cut it up, clean the rot and rebuild. The frame sections were pretty solid.
New corner and side lights all around, reverse LED drive light, LED dome light, USB charger, LED charge level, custom ball holder plate, rebuilt throttle assembly, wheels and tires, brake cables and equalizer, brake assemblies, front spindle bearings, tie rods, front roof support, motor, mounting hardware front springs, heavy duty rear springs, hangers, bushings, shocks, 5 batteries, paint, turn signal assembly, steering column cover and mirror.