1996 Club Car DS — From Worn-Out to Like New!

Parts and tools used in this video: • 4-Pack, 8" 18x8.50-8 White Golf Cart Wheels and Tires - $204.96 (https://a.co/d/6wAbaS2) • Hub Caps for Club Car / Most Golf Carts; Set of 4, 8-Inch - $45.63 (https://a.co/d/4zrm7eC) • Club Car Flip / Folding Rear Back Seat Kit (black) for 1982-2000.5 Club Car - $409.97 (https://a.co/d/buEdYBx) • Seat Back Shell for Club Car DS (Part # 1022370-01) - $52.81 (https://a.co/d/931BpJz) • Front Seat Replacement Cushions, 2-Piece Set for Club Car DS - $291.32 (https://a.co/d/3RIDJUJ) • Seat Handles for 2000-UP Club Car DS (Part # 103246701) - $71.62 (https://a.co/d/93CvFy6) • Seat Hinge for 1979-UP Club Car DS (Part # 1011652 & # 1012412) - $15.76 (https://a.co/d/faHjHOm) • 12V LED Headlight / Taillight Kit for 1993-UP Club Car DS - $75.50 (https://a.co/d/9dvpKNP) • Ignition Switch w/Keys for 1996-UP Club Car DS (Part # 1018263-01) - $16.17 (https://a.co/d/hTcftol) Total Invested in Upgrades / Fix: $1,183.74 Breathing new life into a weathered 1996 Club Car DS gas golf cart can completely transform its look, comfort, and utility. In this comprehensive project, we take on a complete bumper-to-bumper restoration, addressing worn-out components, faulty electrics, and tired seating. Throughout the diagnostic and build journey, we tackle everything from deep cleaning and wheel assembly swaps to custom rear flip-seat installations, front cushion upgrades with correct hardware fitment, and wiring a brand-new 12V LED lighting kit. Along the way, we navigate minor installation hurdles—such as sorting out incorrect hardware on the front upper seat backrest, performing essential fuel system modifications, and dialing in the rear flip-seat alignment. The result is a fully refreshed, street-ready machine that looks and drives like it just rolled off the showroom floor, backed by a total component investment of $1,183.74. WHAT WE COVER IN THIS VIDEO: 0:00 Introduction 1:46 Cleaning 3:10 Removal / Install of Wheels, Tires, Hub Cap 7:48 Removal of old Seats / Frame 12:00 Install of new Flip / Folding Rear Seat Kit 1:25:31 Start of Install of new Front Upper Seat Cushion (wrong bolts) 1:28:59 Install of new Front Lower Seat Cushion and new Hardware 1:35:17 Start of Removal / Install of new LED Light Kit 2:14:50 Removal / Install of new Ignition Switch 2:29:47 Finish of Removal / Install of new LED Light Kit 3:06:23 Finish of Install of new Front Upper Seat Cushion 3:08:49 Fuel System Mods 3:10:25 Rear Flip / Folding Seat Correction 3:15:12 Completion / Before & After If you find this video helpful, consider liking the video, subscribing, and leaving a comment. It really helps support the channel and lets me know what equipment you’d like to see repaired next! #ClubCarDS #GolfCartRestoration #GolfCartUpgrades #GasGolfCart