club car golf cart body

I recently embarked on a project to restore my old Club Car golf cart. The body was showing its age, with significant scratches and fading paint. My name is Bartholomew, and I’ve always enjoyed tinkering with vehicles. This project was a chance to combine my love for classic vehicles and my handyman skills! I knew it would be a challenge, but I was excited to see the transformation.

Stripping Down the Old Body

The first step in my Club Car golf cart body restoration was, of course, stripping down the old body. I started by carefully removing all the accessories – the headlights, taillights, bumpers, and the windshield. It felt a bit like taking apart a delicate puzzle, each piece needing gentle handling to avoid damage. I labeled each part meticulously with masking tape and a marker, making sure to note its position. This was crucial for reassembly later on. Next, I tackled the more challenging task of removing the existing paint. I opted for a chemical stripper, carefully following the manufacturer’s instructions. The fumes were potent, so I worked in a well-ventilated area, wearing a respirator mask and protective gloves. The stripper worked surprisingly well, bubbling up the old paint and allowing me to scrape it off with a plastic putty knife. In some areas, the paint was stubbornly resistant, requiring multiple applications of the stripper and a lot of elbow grease. I found that a combination of scraping and using a wire brush was the most effective method. There were a few moments of frustration, particularly when I accidentally nicked the fiberglass in a couple of places, but overall, I was pleased with my progress. Once the majority of the paint was removed, I thoroughly cleaned the body with a pressure washer to remove any lingering residue. The pressure washer was a game changer, blasting away the stubborn bits of paint and leaving the fiberglass clean and ready for the next stage. It was incredibly satisfying to see the bare fiberglass, revealing the underlying structure of the golf cart’s body, ready for the next phase of the restoration. I took my time and double-checked everything, ensuring a clean surface for optimal repair and painting.

Repairing the Fiberglass

After stripping the paint, I discovered several areas needing fiberglass repair on my Club Car’s body. There were a few small cracks and some more significant chips, mostly around the edges and lower sections where the cart had undoubtedly taken a few knocks over the years. I’d named my cart “The Wanderer,” a fitting moniker given its adventures! For the repairs, I used a high-quality fiberglass repair kit I purchased online. The kit included everything I needed⁚ resin, hardener, fiberglass matting, and a mixing cup. I started by carefully cleaning the damaged areas with a wire brush and then applying a thin layer of resin mixed with hardener to the cracks. I followed the instructions precisely, ensuring the correct ratio of resin to hardener for optimal curing. Once the resin was applied, I carefully laid down pieces of fiberglass matting, pressing them firmly into place to ensure complete saturation with the resin. For larger chips, I built up layers of matting and resin, allowing each layer to cure completely before adding the next. This was a meticulous process, requiring patience and attention to detail. I let each repair cure for at least 24 hours before sanding it smooth. Sanding was critical to create a seamless surface for the primer and paint. I used various grades of sandpaper, starting with a coarser grit to remove excess material and gradually moving to finer grits to achieve a smooth finish. The process was somewhat dusty, so I wore a dust mask to protect my lungs. In a few areas, the damage was more extensive, requiring me to create small patches using additional fiberglass matting and resin. This was a bit more challenging, but with careful layering and sanding, I managed to blend the patches seamlessly into the existing fiberglass. The final result was a body that was structurally sound and ready for the next phase of the restoration – preparing it for paint.

Preparing for Paint

With the fiberglass repairs complete and sanded smooth, I moved on to preparing “The Wanderer’s” body for painting. This stage is crucial for achieving a professional-looking finish. First, I thoroughly cleaned the entire surface with a degreaser to remove any dust, dirt, or residual sanding particles. I used a tack cloth afterward to pick up any lingering debris. Then came the crucial step of priming. I chose a high-quality automotive primer designed for fiberglass. I applied several thin coats, allowing each coat to dry completely before applying the next. This ensured even coverage and prevented runs or drips. Between coats, I lightly sanded the surface with fine-grit sandpaper to create a perfectly smooth surface for the topcoat. This meticulous sanding is essential for a flawless paint job. After the primer had fully cured, I masked off areas I didn’t want painted, such as the lights, bumpers, and any other components that would remain on the cart. I used high-quality painter’s tape and masking paper to protect these areas. I took my time with this step, ensuring a clean and precise masking job to prevent any paint from bleeding onto unwanted areas. Before the final painting stage, I gave the entire body one last thorough inspection, carefully checking for any imperfections or flaws that might affect the final finish. I even used a bright light to check for any subtle imperfections. This careful preparation was time-consuming, but I knew it would be worth the effort to ensure a high-quality finish on my restored Club Car. The preparation was just as important, if not more so, than the actual painting itself. The final result would be a testament to my dedication to detail.

Painting the Body

Finally, the moment arrived to apply the paint! I chose a vibrant, glossy Caribbean blue for “The Wanderer,” a color I felt perfectly captured the spirit of leisurely golf cart rides. I used a high-quality automotive urethane paint, known for its durability and beautiful finish. I applied the paint in multiple thin coats, using a high-quality spray gun. Each coat was allowed to dry thoroughly before applying the next, following the manufacturer’s instructions carefully. Between coats, I used a very light sanding with extremely fine grit sandpaper to ensure a perfectly smooth surface. This process took patience and precision; I wanted an even, streak-free finish. After the color coats were applied and dried, I carefully applied several coats of clear coat. The clear coat protects the color and provides a deep, glossy shine. Again, I meticulously sanded between coats with super-fine sandpaper, ensuring the surface remained flawlessly smooth. I used a high-quality automotive rubbing compound and polishing compound to achieve a mirror-like finish, removing any imperfections or orange peel. I spent hours carefully polishing, making sure the final result was worthy of my effort. The transformation was incredible; the dull, faded body was now a stunning showcase of color and shine. It was a truly satisfying experience to see my hard work pay off. The vibrant blue paint brought a new life to the golf cart, and I couldn’t wait to see the final result after reassembly. The painting process was the most visually rewarding part of the entire restoration, but it required just as much care and precision as the earlier stages.