Cushman Lithium Conversion and Test Drive

This covers electric vehicle system components and lithium battery conversion which I hope will be helpful and educational. At the end I included a test drive and new parts purchased for the next project.

[@Mprikiman]

After I have seen the wheelies and the craftmanship, I subscribed :D

[@DOSputin]

Same!

[@ljprep6250]

Ditto. Now to watch the next vid to see about balancing and charging properly.

[@prestonhill9320]

Same

[@ErkkiPalmu]

Hey man, you got some serious skills! This hands on stuff is very fun to watch!

[@2jeffs1]

I thank you for your kind thoughts and stopping by Erkki, Jeff!

[@wkualum3194]

jeff, I love the videos. I wish you were my uncle. lol. I'd love to be able to download a smidge of your smarts.

[@2jeffs1]

It takes years, (too many) so much to be known. When I moved here in 1986 thought I knew a lot. Looking back - well... Everyone has there own thing they are good at. The more people one knows is a good thing.

[@alexoliva2012]

Hi this is a great project. How is it holding up what kind of range are you getting per charge. I love the paint job. What is the paint brand and code. Thanks for sharing. Thanks Alex

[@2jeffs1]

Hello Alex. Roughly 3-4 hours, many variables to that figure. Haven't noticed any drop in run time or power yet either. Awesome! I am beyond happy with those battery's. Would never go back to the DS ones. They are holding out great and know it would be due for another set of them by now for how much that machine gets used. The paint was from the Kubota tractor dealer. They also had the hardener additive there too. It was the same paint they use on my Kubota B2910. Have a good one Alex, Jeff.

[@deankoch7305]

That's bad ass.

[@startv7472]

Great craftsmanship mate. Could you mention plz how much total voltage u got? Do u need to take care for these lithium batteries?

[@2jeffs1]

That was 57 volt total. The Cushman gets used almost daily, It's been well over a year and still haven't had to equalize the batteries. I do charge them at a low rate of around 10 amps and slightly below the permissible peak voltage charge which is supposed to help with longevity.

[@57WillysCJ]

I have a battery charger question. I have a new Schumacher charger that looks like the one you have and it won't charge a dead battery. I put my old Schumacher on that I have had for at least 25 years and it will charge the battery. The new one will charge a low battery but shows an battery is no good light and won't charge a really dead one. Even my Schumacher load tester says the battery is fine. The new one isn't doing much good.

[@2jeffs1]

I know most new chargers have a minimum voltage before they will start charging. Usually around 2-6v. I believe they do that to confirm the proper polarity before starting the charge so at times one needs an older charger to get started then switch to the new one. Possibly not your issue, just wanted to be sure on the info presented so not overlooked. On another note a while back I bought 2 Schumacher 12v car chargers. Same model, 1 was different looking inside thru the louvers and made overseas. Guess what? yeah - that one was defective! I hope this helps you out for your issue, Jeff.

[@57WillysCJ]

I believe it is the minimum volt issue. I have heard of others having the same trouble including one youtube fellow. I will keep an eye out for another old charger that is in good shape. I end up loaning my charger to family and friends and after 25 years, it is in tough shape but still works. I try to keep at least two good ones on hand. Thanks for your time and consideration.

[@ZulkSOD]

how expensive would this be to do on a 36v club car?

[@onegreenev]

Should be pretty reasonably priced. If the Club Car is already electric all you need is a good controller and some Leaf Modules. 5 modules makes a great 36 volt system. I have a self propelled walk behind John Deere 36 volt electric mower and I now have 5 modules connected and it works great. Charger works good too and will shut off if the voltage goes too low.

[@tommypayne1980]

I think you need wheely bars on the back

[@_mrv_]

The cleanliness of your shop is insanely impressive.

[@kennethrosbury2819]

I'm a welder and a fabricator also and I can really appreciate the inventions that you made and I just wanted to let you know that they're very cool and thank you for your videos signed Ken Rosbury

[@2jeffs1]

Hello Kenneth. Always hearing what others do. Thank you for stopping by and leaving your thoughtful comment, Jeff.

[@AntonBabiy]

Dude! That thing is awesome and the quality of work is amazing! You totally inspire me to get off my ass and finish some of my own projects 😉

[@danonino22]

24:06 Holly Shit!

[@JustWasted3HoursHere]

Awesome information! You sound almost exactly like Elwood Blues (from the Blues Brothers). Say "It's got a cop motor, a four hundred and forty cubic inch plant. It's got cop tires, cop suspensions, cop shocks. It's a model made before catalytic converters, so it'll run good on regular gas. What do you say? Is it the new Bluesmobile or what?"

[@Fentertainment]

@2jeffs1 How has the battery conversion held up? Are you still using the same pack? Any type of update?

[@2jeffs1]

They still seem as good as the day installed. Will never purchase a deep cycle again.... Not only that but a lead acid battery blew up in my red restored Nova. Not happy.... (Interstate) Really...

[@Fentertainment]

@@2jeffs1 thank you sir.

[@Somun-a]

At 20:55, I would suggest that you invest in a proper crimp tool. Soldering is not the way to go. Soldered part of the cable will create tension (cable is not flexible where it's soldered) and eventually cause cracks and connection failure.

[@k9forkids]

24:07 I totally did not expect that. That was fun

[@iammongo2106]

Ooh, that next project looks dangerous. I like it! And I subscribed!

[@raymondj8768]

new sub you blow me away dude your one crazy dude hahaha !

[@okazo81]

what a monster cart lol crazy !!

[@davidgray1877]

that things bad ass ,man your crazy and smart thx for your videos I enjoy

[@shiyiyin3403]

24:04 should be the beginning to attract viewership

[@2jeffs1]

Thank you for your advice, you're totally correct!

[@fc3sbob]

That's great, I drive a lot of these from time to time. I didn't know they made them that long ago, this looks nearly identical to fairly new ones. That being said, I don't know if the ones I've used and seen are new or have been redone, but they are popular in the greenhouse industry. Everyone seems to have them and they are mostly used for hauling long trains of produce to the packing area's because they can pull a lot of weight. I have also never seen one do a wheelie.. lol

[@JustWasted3HoursHere]

Me: I wonder if the torque has been improved on this vehicle. [24:02] Um, yeah, I'd say so! The smile on your face at 24:51 confirms it: Operation successful!

[@2jeffs1]

Great comment, yup - that first test drive is always.....Wee!

[@michaelanderson9792]

Barking bird LOL!

[@grokshop]

Ahhh... the magic shop upstairs, aye?? I knew I was missing something!

[@meb3153]

Hey do you have any updates? (Longevity/Brands info) We have a Titan I want to swap out and upgrade the 6 x 6v... Thanks!

[@ProfessorMiketheMechanic]

I'm interested in making a 48v battery pack for my golf cart. I wish you would go into detail of how you made your battery pack.

[@tomaszklugiewicz3057]

Hi what kind of reverse and forward switch are you using? and how meny Amps hes Your selenoid?

[@robertpryor7225]

Wow, I was going to suggest that Tesla drive train, never mind! He's a good driver too!

[@WillieStubbs]

Holy Craporoni! I know some techs that would love to get around my plant site in one of those.

[@oogie-boogie]

dude,,, nice snow,,:) burrrrrr

[@TheSaabsaab]

He $#!! Himself 😆🤣😂😹😆 as he took off 🤣😂🙄😳

[@fpn78]

t'es un malade Jeff! you are a genius great demo thanks for showing

[@bradleyawinter]

What do you use to charge the lithium pack? Do you have a bms?

[@vwbeetle5578]

Take that thing to a drag strip. 60' record coming up

[@Good-Enuff-Garage]

crazy SOB, jk, great video

[@BeginningfromthisMorning]

Great video! We are using the same batteries as an RV "house" source.

[@not2fast4u2c]

I did understand some of the electrical stuff ....Great job on the mechanical parts ..making all the brackets and stuff and the tools you use is always good for me to watch ...Be care full on that thing ...You may have to build a Wheelie Bar !!!

[@2jeffs1]

I have several friends saying that too. There is one guy who says he'd love to have the Cushman where he works. When I ride with him in his car that imaginary brake pedal needs to be there and functional.

[@realoldgeekster]

2jeff1 I heard you mention in the video where you took apart a Nissan leaf battery and pulled all the batteries out. You had plans to use the case holding the batteries for something. I searched but could not find any video. Is this still going to happen? I have 2 cases and also want to make something with them. Any updates? I love your channel and have learned plenty from you. Thanks You for opening this channel for us. Mike realoldgeekster

[@2jeffs1]

Hi Mike. The vid of the battery case/pack dissemble in case you meant that. kzbin.info/www/bejne/ZpWlm4Otf8SEl9k Did save the shells, no use for them - yet! So glad to hear my channel helps you out. That's the big reason I so enjoy doing this!

[@jwsolarusa]

You are very intelligent. Thanks for sharing

[@deangeloahayes]

That was awesome. Clean build.

[@CraigArndt]

The Cushman is a speed demon, what a ride! Those battery packs look so high tech and sleek, way better than those deep cycle batteries. The Tri-Moto at the tail end is gorgeous, looks new, can't wait to see the next project.

[@2jeffs1]

Hi Craig. Those deep cycle I had in there weren't even a year old and one was going down hill already. At times when out on a romp just 1 time the dod gets quite low which is bad on them. With those new batteries I've been getting 4-6 romps on one charge. Switching a lot of things here to them now. Seems weird to come in from a romp and not have to put the charger on!

[@chrissscottt]

Very cool. You're a clever man.

[@Rick_Foley]

Better than "Downtown"

[@joemiles572]

do you have to have the motor controller ? I want to put the battery setup in my club car precedent that already has a controller

[@2jeffs1]

Yes. That controller is much more HD then the factory one. It was the highest output one they sold. That does make a difference for sure.

[@sc7983]

Hehe that looks so much fun

[@IBRACIN]

I love your shop and the things you do, much like how I do things, I would like to do this to my 2007 EZGO MPT It's like a golf cart... with a dump bed....what are you using to charge the pack, and i need to find a pack to break down, seems to be hard to find at a good price in washington state..

[@theinterfaithshepherd9075]

I wish I had a shop like that to call my own!! How do you earn a living? (probably wrote a program to trade stock automatically) I am confused about the circuit diagram and how everything was plugged in and so forth. So my feedback is that it would nice to see a whiteboard sketch of the system. I love people who are so creative and share!!! Thank you! :)

[@webmonkees]

I'm wondering what combination would work in a Super Beetle, just enough to get to normal speeds, relatively. More range than derange.

[@michaelyungman2767]

Great job! I am in the process of converting my 48V golf cart to lithium-do you have more information on where you located the battery packs/BMS system? That would be helpful

[@BlakeGJ]

What a great use of LEAF batteries! I love my LEAF, but I'd love to build an electric motorcycle!

[@drogers270]

Do you have a component list for lithium conversion? I have two ezgo 48 volt txt carts that I’d like to convert to lithium.

[@chipwright6193]

Great video Jeff! I learned a lot from it. It's hard to believe that your Cushman was in that bad of shape when you first got it, but you would be the one to make it look better than new. That thing really moves!

[@epicnaturals4763]

i worked all day. tired af, and here i am watching you work, already after midnight; yet loving every minute of it. being addicted to the shop is both a blessing and a curse.

[@sarahmartin3558]

I may be an Industrial Designer, but, most of those electric components were Greek to me! LOL!

[@leonieburnham322]

Very very cool...was expecting a sedate nana shopper...not ludicrous mode.

[@Lefthandylemmons]

Any ideas for just straight up replacing my Taylor Dunn's six 6volt deep cycles with lithium? Not for more power but just because 6 volt deep cycles cost an arm and both legs!

[@2jeffs1]

Hi there, yes have been asked times before. Deep cycle batt's are a ripoff for the short life they have. Lithium are the real deal. Unfortunately they are expensive and require special charging procedures too. Where I bought that entire electric car battery - 48 - 8 volt cells cost me $2,500.00 which actually a deal compared to e bay prices of 110.00 per 8 volt cells.

[@Lefthandylemmons]

@@2jeffs1 Yikes! Well, I guess that is why I got such a deal on the Taylor Dunn. lol

[@davidr1997]

Great work! Im using electric to! Amazing torque and speed! Well done conversion! Keep it up! Subbed!

[@051570orion]

we have Cushman's like that in the plant I work in bunch none of them are that fast , and the makes me wish I had never gotten rid of my golf kart I would have liked to to that to it and with your videos it would be a great help .

[@doppler3237]

that is bad ass. sub'd !

[@bobbrawley9439]

The batter compartment with the Lead acid batteries were immaculatly clean , polished , buffed and bristling. The Century Machinery bandsaw showed not a sparkle of chips, grease, water staines in the chip tray . Jow do you do it. How do you spit shine industrial contraptions , and machinery? I don'teven see residue from dried water drops so having a powerwasher is no excuse

[@2jeffs1]

Hello Bob. For the lead acid I am using those microprocessor controlled staged chargers. The chargers that come with the golf carts, I call them battery cookers. A friend just told me yesterday that he left his on one time for a week and had to clean up the acid mess on the floor. To clean off the saw there is a cent vac tap right there, and by the drill press too (never thought of showing that) and vacuum it off when done using it. Rarely wipe things off where it might look like that. Do have a vid on the central vac setup if you would be interested. Thankx for stopping by, Jeff

[@AesirLongschlong]

Bob Brawley I can attest to the cleanliness of his whole shop. The central vac on his machining equipment is nothing short of perfect. As always, Jeff is the greatest genius I know. ML

[@deejohnson5163]

I loved when you popped a wheelie. I really like the upstairs of the shop. Been hooked since i watched the waste oil heater.

[@82stuntman]

Great fabricator and one crazy SOB. I like this guy!

[@skipsteel]

Looks like a very professional job, I hope it handles slow speed stuff well.

[@DEG1985]

Great video!

[@JustWasted3HoursHere]

The check from Cushman should be in the mail by tomorrow.

[@StephenDanielAddeo]

Good call on the front end. It looks really great now. You are a brilliant mad man Jeff.

[@aatheus]

Nice build video! that looks like way too much fun to ride around.

[@Superduty_59]

Another awesome video Jeff! That Cushman has came a long way since you started.

[@danlunn7868]

wheelie king

[@felixthecat5416]

Awesum man loved ur first circle in the snow that tugs got sick power

[@raymondj8768]

you have a really nice shop and do great work your a smart dude ! really good video work to !!!

[@wyattoneable]

That dude is wicked fast! It sounds like a space ship from a Star Wars film. Amazing work and well explained.

[@2jeffs1]

Thanks. There are only a few things here that I bought new but seeing them in a video without the before and after one wouldn't know that. I always thought it would be neat if the original owners of these project could see them.

[@gregfoster6916]

What do you use to charge that? Do you need a BMS??

[@2jeffs1]

I am using the Interactor battery charger (was for the deep cycle batteries) which I modified for charge rate and cut out voltage. I checked the balance several weeks ago and it is spot on, no need to adjust. The battery's were all from the same pack which I believe is important. Also I been charging them to around 85 - 90 percent which is supposed to be better for them. Do have a video on the BMS's I am using/bought.

[@markjennings2315]

Boat conversion??? That would be neat!

[@knewledge8626]

I could be wrong, and in fact I often am, but it doesn't look to me like that center row of busbars is necessary.

[@2jeffs1]

Good question. The machine would work without them connected. That keeps cells more equalized and the battery monitor is connected to those so all cells can be monitored for variance.

[@knewledge8626]

@@2jeffs1 👍

[@skmetal7]

The Tesla Tugger! I so needed this when I worked at Fedex.

[@Cr125stin]

Awesome video as always. Very informative! Ive had some experience with ev's I can't wait to see what's next!

[@gildardo]

Thanks for sharing, I enjoyed watching it.

[@johnnymossville]

Jeff, that's a beautifully built machine. Nice job.

[@nonyourbuz5805]

.....Nice Garage-Storage....I'm curious just what you do/did in Life....You seem to have knowledge in many areas....

[@2jeffs1]

I've been self employed since 1982 in the automotive repair business. Started the business when others were asking for me to do things for them. Much is self taught. Always liked taking things apart to see how they worked and liked a challenge to build or fix anything especially something different. I always tell others don't let anything intimidate you. I look at everything as - if someone was able to build this I should be able to fix it. There will be fails on occasion, every day is a learning experience to benefit in so many ways. Hands on is the best way to learn and see things. Having to pick up the phone and have someone do something can be costly. Being handy is what got me where I am today. Many things one sees in the background of the videos came here in rough condition, which I couldn't afford if in good condition. I have helped many people out on odd things thru the years, can't take credit for how many others helped on projects here too in return. Thanks for stopping by, Jeff.

[@02oilburner]

Great project!! I subscribed immediately! I cant wait to check out what else you have. I have a Alltrax 500 amp controller in my 2015 48V EZGO TXT. Do you build these batteries to sell? Id be interested in pricing if so.

[@2jeffs1]

Hi there. no I don't sell the batts. They sell them on e bay but.... I would prefer the used ones from the same pack and from cold climate to get the best bang for your buck!

[@ricklocicero4194]

Where do you purchase the battery cells?

[@2jeffs1]

E bay sells separate cells for 110.00 per cel. I bought the entire case which holds 48 cells which is half that price per cell but had a use for all.

[@stretch44875]

time for a selectable locker!

[@2jeffs1]

That would be great feature to have!

[@jrgenthomsen8692]

Thanks for sharing, You are a cool guy, and you love what you do, and we 2. That just tells it all, the new battery tech are much better then the old stuff, and get the volt up and the amp up 2 give a lot of power.........Nice job Best 2you....Jørgen Thomsen Denmark DK

[@2jeffs1]

Where I had those batteries in there for a while now couldn't be happier on how they are holding out with no loss in performance. 100 lbs lighter and 4 times longer on run time, perfect! Thank you for stopping by Jorgen, Jeff.

[@andrenunes1888]

very good!

[@oogie-boogie]

i have a battery question,,.. im thinking about making a 12volt battery pack out of the lithium leaf batteries,,,but 1 is 8 volts and 2 is 16..soo do you just not charge it fully?,, i would lit to replace my flooded batts,, at 220ah with leaf batts

[@2jeffs1]

You are correct - they would not be fully charged. The chargers I am using have been modified to reach the full charge voltage. I will say that I would never consider switching back to flooded battery's after experiencing the quality of those Leaf batts!

[@ronaustin5848]

Jeff, I have to say I am not a car guy but watched the entire video. A Lot of it went over my head, some didn't. Very cool video, you would make a good instructor for some like me. Wish I had a shop like yours to work in, a 1 car garage I share with my wife's washer/dryer leaves me with a small shop space. Thanks again for the vid. Ron

[@2jeffs1]

Really enjoyed reading your write up Ron. It is fun to create different things and do put a lot of thought in each video trying to explain the reasons to the madness! ;>)

[@mrJMD]

You sir are a hero! That wheelie was epic! And I got a suspicion that you favorite football team is DA BEARS! DAAAAAAAH BEARS!

[@2jeffs1]

Big smile here at this end from your comment for sure!!! Not really a football fan tho. Gotta have gas or electricity involved - to peak that fun factor!

[@Steve_Just_Steve]

Your awesome! -A- vertical torque -curve- is a beautiful thing! If I didn't know any better I'd almost say that you enjoy the added adrenaline that comes with the instability of having 3 wheels and no suspension. lol. Can't wait to see lil' three wheeler go! Had one almost just like it 20 years ago.

[@2jeffs1]

You got that right, a true scare ride on a 3 wheeler. Should have more power yet than the existing engine. Really enjoying how much longer one can go on those new batteries too!

[@ericrichardson9754]

Just bought 1 of these in a Cushman & 1 Taylor Dunn & have to do this conversion on at least 1. Both are in great shpe but what did the lithium ion conversion cost aprox & where to get the parts> Thanks for a gret video & how fast will it go? Thanks!

[@2jeffs1]

Unfortunately one can spend a considerable amount of money on these projects but they are so much fun when done. I doubt it would be practical for you to buy an entire car battery here is a link to purchase those cells. hybridautocenter.com/HAC4/index.php?option=com_hikashop&ctrl=product&task=show&cid=91&name=58ah-nissan-leaf-battery-module&Itemid=605 For motors and controller stuff this is a good source. www.evdrives.com/Default.asp Currently it will go 35 mph but still working on getting more with a better field map.

[@MrMuzikbum]

Dude…that is AWESOME!!

[@kevinedward1234]

Jeff, another top drawer video!!!!!!!!!

[@Cesaleo78]

Great video, you made that look too easy. I have a few Taylor Dunn carts I would love to convert as you did. Could you sell me a plan and a break down of the parts needed along with a wiring diagram?

[@2jeffs1]

Hi Cesar. I never keep track of things here where there is a constant new project going on. (Sorry - don't do paperwork) Not only that I am currently laid up from a bad crash, broken femur, ribs, not real well. For a good source on products and wiring diagrams which I used was this place here. I used the easy go setup for info/design. Seemed the most basic. alltraxinc.com/ You can call them to see what might be the best components to use for your particular setup. I would recommend read/learn a bit first off there articles first. Then this place is where I order all the parts needed from. Nice people, best pricing. www.evdrives.com/Default.asp Good luck.

[@lyndonbarton]

cool stuff looks like alot of fun wow.

[@2jeffs1]

The work involved is all worth it when one finally gets a ride! Thanks Lyndon.

[@johnwallace7465]

Great video Jeff! I didn't think you could make that Cushman any faster than it was before..lol

[@2jeffs1]

Got me smiling on your comment John, Thanks!

[@sylvainhamiaux7984]

Just great Jeff, Thank you, How do you charge the lithium battery pack?

[@2jeffs1]

I modified several chargers that I had for that. Showed one of them and what I did on the battery monitor install video. kzbin.info/www/bejne/eaCac4GJeqaaf68

[@williamzoom]

Is that a 81 Tri Moto? I know someone with a Tri Z, got it new for Christmas in 85 and it's still in really good condition.

[@2jeffs1]

I think that is an 84? That is one of the few things I actually bought new here. Those are so much fun, too sad they quit making them where too many people got hurt on them.

[@juanescalera7489]

con estas baterias podria remplasar las baterias pesadas para mi trans am