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I'm converting my old golf cart from lat
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acid batteries to lithium but I don't
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want it to cost more than the cart is
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actually worth which might be I don't
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know $1,000 on a good day stick around
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I'll show you what I got going
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on I am so done with lead acid batteries
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this is the third set I've had in this
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golf cart and these are now toast also
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there's a myriad of problems with this
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type of battery and replacing them with
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the same type doesn't make any sense
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when the alternatives are so much better
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and affordable now and therefore now
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that I have to replace these I'm going
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to be switching over to a lithium
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battery now converting your golf cart
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from lat acid to lithium is not quite as
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simple as just pulling out all your
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batteries putting a lithium battery in
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hooking up a couple of cables there's a
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little bit more to it than that I've
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ordered the specialty components that I
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need to complete this conversion from a
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few different sources now this is not
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going to be some long unboxing video but
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I will provide more information on the
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components as I install them just an FYI
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this is not a detailed step-by-step
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instruction video on doing a lithium
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conversion but rather an overview of the
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steps involved with some good to know
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information along the way however if you
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have any questions about anything in
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particular leave that in the comments
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and I'll respond with as much detail as
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I can now let's take a look at the
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battery this is the loan battery that
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I'll be installing It's a 36v 65 amp
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lithium iron phosphate battery from
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enjoybot with self-heating self-heating
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what's that lithium cells can be damaged
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if they're charged when the temperature
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is too low self-heating batteries have a
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heating element that will warm the cells
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before it allows the battery to be
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charged I use my golf cart year round to
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get around the farm and I live in
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Michigan so there will be times when I
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need to charge the battery when it's
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freezing outside so this feature is a
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must for me obviously not something that
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everybody would need self-heating is
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just one of the functions that's handled
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by the battery management system or BMS
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a component that is internal to the
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entire unit it also prevents
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overcharging and overd discharging both
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of which can damage the battery a
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protection that lead acid batteries
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don't have the lead acid battery Ray
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that this is replacing has a rated
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capacity of about 200 amp hours so doing
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quick math you might say hey the new
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battery you're putting in has only one/
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third the capacity as the the old
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battery pack and thus only 1/3 the range
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well not really because rated capacity
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Works a bit differently with lithium
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batteries realistically you can only use
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half the amps of the r capacity of a
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lead acid battery or risk causing damage
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therefore you only have 100 usable amp
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hours from a 200 amp hour battery
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whereas lithium batteries can safely use
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100% of the rated capacity although for
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the most part you're not going to want
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to go much past 95% depth of
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discharge so if we redo the meth with
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that in mind the 65 a hour lithium
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battery has 2/3 the usable capacity as
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the old lead acid battery pack still not
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as much however consider that the
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lithium power will also weigh 330 lb
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less that's a third of the weight of the
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golf cart that will make up for some of
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the smaller overall capacity as the cart
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will be more efficient therefore you can
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really stretch your amp hour dollar the
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65 amp hour lithium battery is a common
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size to swap in for a two-seater golf
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cart you'll also see the 100 amp
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batteries used for greater range my cart
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doesn't have the room for one large
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battery unless I move the drive
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Electronics basically the speed
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controller solenoid and throttle realat
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to the side here which involves a bunch
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of fabrication that I don't feel like
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doing besides I can't find a 100 amp
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hour battery with the self heater anyway
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so the 65 it
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is this is a specialty tool it's a
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battery lifter that I have because I've
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done this job several times before and
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I'm happy to report that this should be
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the last time have to use the stupid
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thing I think it's a miracle that I
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actually found it since I last used it
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four years ago uh that's not to say that
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I can't lose a tool that I used 4
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minutes ago because that's a thing with
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me it's a good idea to take pictures of
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all the connections to the positive and
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negative hookups of the battery array
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before starting to disconnect anything
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as I'm unhooking all these batteries
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that are connected in series it reminds
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me of another benefit of this lithium
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swap the new setup will be simpler with
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less cablage and yes cablage is a word
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now and that means less points of
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failure I have had breakdowns where a
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cable was the problem it's interesting
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now that I'm editing this video and
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watching this part and fast forward just
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how much the ride height of the cart
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keeps increasing as I continue to pull
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the batteries out and keep in mind the
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One battery I'm putting in weighs less
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than one of the six that I'm pulling
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out the battery tray in these cards is
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always susceptible to acceler ated
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corrosion because of the nature of the
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lead acid batteries this one wasn't too
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bad because I've cleaned it up and
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sealed it two times before when I
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changed the batteries so just another
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quick coat of sealer is all I needed
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here also the new battery has a bigger
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footprint than the old ones so it's not
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going to fit neatly into this battery
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tray so I'm going to put a floor in here
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for the battery to sit
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on this is the battery gauge for the old
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lead acid battery pack it's basically a
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voltmeter with a limited scale of maybe
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25 volts on the bottom end and 45 or so
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on top and this worked fine before
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because with lead acid batteries as you
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pull amps out the voltage drops in a
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linear fashion and therefore reading the
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voltage of the pack will give you a good
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idea of the remaining runtime the
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discharge curve of a lithium battery is
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much different it'll come off its peak
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voltage real quick and then sit it its
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nominal voltage for most of the cycle of
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the pack and then at the very end it
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falls off a cliff
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so if you're monitoring a lithium
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battery the same way and you read X
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number of volts you won't know if it's
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here on the graph where you got about
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80% left or here where you're in the
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40s now this graph is showing the
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discharge curve for a lithium ion
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battery but the discharge curve for
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lithium iron phosphate is nearly
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identical as shown here I don't know
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where I got this graph from but voltage
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is spelled wrong with that established
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then we're going to use this instead to
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determine the state of charge of a
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lithium battery this monitor doesn't use
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voltage but rather tracks amps in and
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amps out of the battery to determine the
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state of charge and that is accomplished
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by installing this shunt which is that
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gold block on the right side in line
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with the negative side of the battery
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and all of the current going in or out
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of the battery is measured by that shunt
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and the data is sent via cable to the
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monitor I hooked up the new battery
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temporarily just to take the cart for a
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quick spin to see how it worked and I
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don't have the 12vt system hooked up yet
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thus s lights but bonus this is an older
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cart has a steel body and therefore my
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magnetic work light works pretty good to
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light the way and this is supposed to be
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a temporary solution but it actually
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works pretty
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good although it'll be gone going
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forward I hooked up the new battery to
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the old meter just to see how much of a
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voltage sag there was under load and it
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turns out it's practically zero the
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standing voltage and the voltage gender
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load are nearly identical which is
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awesome and for comparison just for fun
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this is a video I took of the old lead
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acid battery pack before I took it out
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just to see how tired they were and this
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begs the question how much voltage s do
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you want and the answer would be
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yes I need to get behind the dash to get
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this new meter in I've already unscrewed
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and removed the cup holder here the
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bonus about building your dashboard out
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of leftover laminate flooring is the
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sheet metal flange at the top of the
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opening fits right into the factory
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groove of the flooring and then the
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bottom is held in with a couple pan head
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screws and it cleans easily with a
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Swiffer this is the data cable that
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connects to the monitor up front to the
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shunt right back here where I mounted it
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on this back plane and now this is not
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one of those newer carts that has
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channels in the floor where you can run
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wiring up to the front so I need to get
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it through one of these looms that runs
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underneath the cart to the front this is
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stuff that I add did years ago when I
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first bought the cart and this cable
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does need to be protected because of the
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way I used the cart now when I first got
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it it was onroad only but then after I
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bought the farm then I uh right bought
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the farm is not a good term when I
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purchased the farm I brought it here I
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started taking it Offroad into the
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fields and stuff like that and now the
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bottom is susceptible to damage you know
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like this now you're going to love this
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now this box right here this is not
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Factory I added this as an acoustic
08:58 - 09:02
enclosure for for the subwoofers on the
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other side uh now I need to run that
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data cable up through here so I need to
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pull the panel off so I can get access
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and what did I find inside some damn
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chipmunk is using this for a storage
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facility and I don't know when this
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happened because I rarely leave the cart
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outside when it's not in use but this is
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just a reminder of why I hate chipmunks
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and squirrels uh and you know what so
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dog there are lithium battery monitors
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that are round that would fit right here
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into the hole from my old meter but of
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course the monitor that came with my
09:33 - 09:40
enjoybot battery is rectangular because
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of course it is cutting this out to fit
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the new one is going to kind of
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suck here is the lithium battery
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installation the floor I installed over
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the existing battery tray is 3/4 in
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plywood there's a couple locator blocks
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to keep the battery from shifting I had
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some threaded Rod lying around so I put
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that through and attached it to the new
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floor and I designed and 3D printed a
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battery hold
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down and this here is not a hold on
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strap it is a carrying handle for the
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battery which is removable however I'm
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going to leave it on here otherwise I'll
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lose it on a more positive note we'll
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take a look at the connections to the
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plus side of the battery most of the
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wires and cables that connected to the
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positive log on the old battery bank
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will connect here the positive motor
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cable runs to the speed controller as
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before now keep in mind this is a way
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old golf cart so your connections may
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vary especially those where everything
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wires into the controller or has an
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onboard computer one of these 14 gauge
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wires runs to the key switch turning the
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key does what it always did which is
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energize the dry solenoid circuit the
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dry solenoid is that click you here when
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you push on the
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pedal another connection Powers the DC
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todc converter of course that's what
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provides the 12vt power for the
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accessories lights radio and so on now
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that's not a direct hookup it's actually
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switched through this relay which is
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energized when the key switch is turned
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on and that's a new circuit that I
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branched from the key switch now it's my
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understanding that this can be trickier
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with some other golf carts because the
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key switch circuit is deenergized when
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the forward and reverse selector is in
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neutral in which case all your
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accessories will switch off momentarily
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when you change direction not going to
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be the case with mine as that key switch
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circuit is independent so that's good
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and you might ask why does that
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Transformer have to be switched if you
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just turned off all the 12vt accessories
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won't it just stop drawing power from
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battery no even if there's no load on
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the 12vt side the converter will
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continue to use some power not a lot but
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we still need to have it switched off to
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eliminate what is essentially a
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parasitic drain if not in
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use ultimately there'll be another line
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here for the charger possibly it'll go
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to the external Port like before or it
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might be wired into an onboard charger
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that has yet to be
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determined one thing from the original
12:06 - 12:10
cart schematic that used to be connected
12:08 - 12:13
to the positive here that never will be
12:10 - 12:13
again is the reverse
12:14 - 12:18
buzzer I disconnected that nonsense a
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long time ago and even if I wanted to
12:18 - 12:23
hook it back up I couldn't it's only 6
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Vols it was originally bridged across
12:23 - 12:28
the PSE of Just One battery I might even
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just hook it up across the full 36v load
12:28 - 12:34
to fry it on purpose you know just
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because and lastly a new line that goes
12:34 - 12:38
to power the electronics of the shunt
12:36 - 12:41
not only does it need some power to run
12:38 - 12:44
the circuitry but it also supplies power
12:41 - 12:46
to the module on the
12:44 - 12:49
dash and speaking of the shunt and I
12:46 - 12:51
don't mean to be negative here but the B
12:49 - 12:53
minus terminal of the shunt runs with
12:51 - 12:55
the battery cable to the minus side of
12:53 - 12:57
the battery these are the only two
12:55 - 12:59
connections to these terminals
12:57 - 13:02
everything else 36volt grounds will
12:59 - 13:04
connect to the P minus side of the shunt
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that includes the negative battery cable
13:04 - 13:08
that runs to the speed controller and
13:06 - 13:10
also the line for the charger this way
13:08 - 13:12
any current running in or out of the
13:10 - 13:15
battery goes through the shunt and is
13:12 - 13:17
metered back to the DC to DC step down
13:15 - 13:20
converter for a minute sometimes also
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called a buck converter that's Buck
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converter the 12vt line has a maximum
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output of 20 amps and it runs directly
13:25 - 13:29
to the main power switch on the
13:27 - 13:32
dashboard all the 12vt except
13:29 - 13:33
accessories Branch from there I added
13:32 - 13:36
this indicator that's on anytime the
13:33 - 13:38
12vt system is on that way it's a
13:36 - 13:42
reminder that that converter is powered
13:38 - 13:42
up and to turn off the key if not
13:42 - 13:46
needed one of the catches to going to
13:44 - 13:48
lithium though is that you need a
13:46 - 13:50
lithium specific charger and that's not
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necessarily a bad thing especially if
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you have one like this which is about
13:52 - 13:56
the size of one of those old lead acid
13:54 - 13:58
batteries and probably weighs about as
13:56 - 13:59
much as one two it's not exactly
13:58 - 14:02
portable and you're certainly not
13:59 - 14:04
putting it on board the golf cart
14:02 - 14:07
currently I have this portable charger
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specifically for a 36v lithium
14:07 - 14:11
battery so for now this is how I charge
14:09 - 14:12
clamp the positive directly to the
14:11 - 14:14
battery and don't forget we don't
14:12 - 14:16
connect directly to the negative
14:14 - 14:17
terminal but rather the P minus side of
14:17 - 14:21
shunt in the future I'll either adapt
14:19 - 14:23
the charger leads to use an external
14:21 - 14:26
charging port or I might get an onboard
14:23 - 14:27
charger which would Mount right here I
14:26 - 14:30
got the battery monitor set up and all
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the settings in and and uh this could
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actually be a whole video in itself and
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I'm not even sure if I get the settings
14:34 - 14:39
right the instructions were pretty much
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useless I had to do some digging around
14:39 - 14:43
on the internet to see uh what some of
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these settings might be and again I'm
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still not sure if I have them right but
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I think I have him close enough to be
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able to do a little
14:48 - 14:53
testing right now I'm sitting in the
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cart still uh I don't mean I'm still
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sitting in the cart I mean I'm sitting
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in the cart and I'm not moving the
14:57 - 15:02
cart's not moving and what the battery
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monitor is telling me is that there are
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60 amp hours left in the battery which
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is 94% full the current voltage is
15:08 - 15:14
39.4 it's drawing 1.51 amps right now
15:11 - 15:17
because the lights are on uh and that is
15:14 - 15:20
59.9 watts and it can sustain this state
15:17 - 15:22
for almost 39 hours before the battery
15:20 - 15:25
goes dead of course most of these
15:22 - 15:27
numbers are going to change once I start
15:25 - 15:29
driving before I go out for my little
15:27 - 15:31
late night test drive couple couple
15:29 - 15:33
things I want to mention not related to
15:31 - 15:36
the battery swap per se but it is golf
15:33 - 15:37
cart related as I mentioned earlier this
15:36 - 15:39
is an older golf cart and it has this
15:37 - 15:41
stubby little Ford reverse selector at
15:39 - 15:43
the front of the seat pedestal I didn't
15:41 - 15:45
realize how awful and awkward it was
15:43 - 15:47
until I got this aftermarket shifter
15:45 - 15:49
lever so much easier to reach and less
15:47 - 15:51
effort to move if you have a cart with
15:49 - 15:54
one of these little shifters down by the
15:51 - 15:56
floor I highly recommend one like
15:54 - 15:58
this it's dark outside right now and
15:56 - 16:00
that reminds me of something else and
15:58 - 16:02
that is those dags with these obnoxious
16:00 - 16:03
lighting setups the ones that drive
16:02 - 16:05
around the campground blinding everybody
16:03 - 16:07
they pass on the road and all the people
16:05 - 16:09
sitting around their campfires and they
16:07 - 16:11
Disturbed the wife and kids who are
16:09 - 16:13
already asleep in the camper this is my
16:11 - 16:16
more reasonable lighting solution two
16:13 - 16:18
six element single row LED driving
16:16 - 16:20
lights they light up just what I need to
16:18 - 16:21
see and not a bunch of stuff I don't
16:20 - 16:23
they're small and they can be mounted
16:21 - 16:24
out of the way where they're not
16:23 - 16:26
susceptible to damage and they're not
16:24 - 16:29
using three times the amount of power
16:26 - 16:31
from my battery than necessary
16:29 - 16:33
okay now it's time for a test drive and
16:31 - 16:36
I really can't compare this to say you
16:33 - 16:37
know a fresh set of lead acid batteries
16:36 - 16:40
cuz it's been you know 4 years since I
16:37 - 16:43
had those but I'm sure it's peier uh I
16:40 - 16:45
don't see how it couldn't not be and
16:43 - 16:47
it's driving exactly how it's supposed
16:45 - 16:50
to and now what I'm not going to be able
16:47 - 16:52
to do right now is do a range test just
16:50 - 16:54
because of the conditions it's been
16:52 - 16:55
raining like this for 2 days and we had
16:54 - 16:57
about a foot of snow on the ground
16:55 - 17:00
that's all melted now so there's a lot
16:57 - 17:03
of water that driveway is pretty soft
17:00 - 17:05
and muddy lots of Puddles all the other
17:03 - 17:07
areas the fields and the grassy areas
17:05 - 17:09
are pretty much all water logged and
17:07 - 17:11
swampy so there's nowhere I can drive
17:09 - 17:13
right now that's not going to have a lot
17:11 - 17:15
of added rolling resistance that I
17:13 - 17:17
normally wouldn't have and they're
17:15 - 17:19
calling for rain over the next couple of
17:17 - 17:22
days still and so this place isn't going
17:19 - 17:24
to dry up anytime soon therefore the
17:22 - 17:26
range test is going to have to wait for
17:24 - 17:29
another video so keep an eye out for
17:29 - 17:33
and now the big question that some might
17:31 - 17:35
be asking right now what'll it cost man
17:33 - 17:38
what will it cost at the time of this
17:35 - 17:40
recording March of 20125 a combination
17:38 - 17:43
of purchases through the enjoybot store
17:40 - 17:45
and Amazon a system similar to the one I
17:43 - 17:48
just installed would cost right around
17:45 - 17:50
$800 now the reason I say a system quote
17:48 - 17:52
similar to mine is because the offerings
17:50 - 17:55
features and package deals seem to
17:52 - 17:57
change regularly more specifically that
17:55 - 17:59
price includes an onboard charger and
17:57 - 18:02
also Bluetooth in the battery which mine
17:59 - 18:04
doesn't have and $800 is less than a new
18:02 - 18:06
set of lead acid batteries and the
18:04 - 18:08
lithium battery has a 10-year warranty
18:06 - 18:11
lead acid golf cart batteries have what
18:08 - 18:13
a oneyear warranty maybe I'll put my
18:11 - 18:15
affiliate links in the description for
18:13 - 18:17
both the enjoybot store and Amazon for
18:15 - 18:19
some of the other golf cart related
18:17 - 18:21
items shown in this video however be
18:19 - 18:23
sure to do your research first
18:21 - 18:26
especially with BMS rating if you load
18:23 - 18:27
your golf cart heavy or pull Hills a lot
18:26 - 18:30
you may need something with more than
18:27 - 18:32
100 or 120 amp's continuous
18:30 - 18:34
discharge to restate what I said earlier
18:32 - 18:36
if you have any questions on specific
18:34 - 18:38
details of the install or the components
18:36 - 18:40
be sure to ask them in the comments and
18:38 - 18:43
I'll be sure to respond as quickly as I
18:40 - 18:45
can I'll be continuing to evaluate this
18:43 - 18:47
setup further and follow up with videos
18:45 - 18:49
including a range test as soon as the
18:47 - 18:51
conditions are more typical so be sure
18:49 - 18:53
to subscribe so those videos will come
18:51 - 18:54
up on your feed when I release them
18:53 - 18:56
thanks for watching and we'll see you
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