Transforming a standard electric golf cart into a capable 4×4 side by side involves extensive drivetrain and chassis modifications, but with the right approach, it’s achievable and rewarding.

Why Convert an Electric Golf Cart into a 4×4 Side by Side?

An electric golf cart is quiet, clean, and efficient, but it’s typically designed for flat terrain and smooth surfaces. If you want to tackle trails, farms, or hilly backwoods, upgrading to a 4×4 side-by-side platform gives you more control, power, and all-terrain performance. While buying a new utility terrain vehicle (UTV) is one option, repurposing your existing cart offers a more budget-conscious and customizable solution.

Step 1: Drivetrain Conversion

The most critical step is replacing the standard rear-wheel drivetrain with a full four-wheel-drive (4WD) system. Golf carts usually come with a single electric motor driving the rear axle. To build a real 4×4 side by side, you’ll need:

• Dual motor system: One for the front axle and one for the rear axle, or a mechanical transfer case from a donor ATV or UTV.
• Front differential and axles: These must be custom-mounted onto the front subframe.
• Driveshaft and coupling system: For mechanical 4WD solutions, driveshaft alignment and coupling strength are key.
• 4WD controller or selector switch: To allow engaging/disengaging the front wheels depending on terrain.

Electric motor coordination is essential—synchronizing power delivery to both axles avoids tire scrubbing and overloading one end of the drivetrain.

Step 2: Chassis and Suspension Upgrades

The factory golf cart frame isn’t built to handle off-road stress. Reinforcing the chassis or replacing it entirely may be necessary:

• Custom tube frame or subframe reinforcement: Helps withstand shock loads from uneven ground.
• Independent suspension: Install A-arm or long-travel suspension kits front and rear for better articulation.
• Lift kit: Most 4×4 conversions require a 4-6 inch lift to accommodate larger tires and axle clearance.
• Heavy-duty shocks and springs: Opt for coil-over setups or ATV-compatible shock absorbers.

These upgrades allow for better ground clearance, smoother rides, and improved durability in demanding environments.

Step 3: Power Source and Electrical System

Since you're working with an electric golf cart, ensure your battery pack and controller can handle increased demand:

• Upgrade to lithium batteries: They are lighter, more efficient, and deliver more consistent voltage under load.
• High-amp controller: Consider replacing your stock controller with one that supports 400A or more for dual motor systems.
• Cooling system: High-performance components may require additional cooling (fans, heatsinks, or even liquid cooling).

Step 4: Tire and Brake Enhancements

Larger, knobbier off-road tires improve grip, but may also demand better braking and steering systems:

• All-terrain or mud tires: Choose 23”–25” tires with deep lugs.
• Hydraulic disc brakes: Upgrade from mechanical drums to hydraulic discs for stronger and more reliable braking.
• Beefed-up steering components: Heavier tires and terrain stress require reinforced tie rods and bushings.

Step 5: Additional Accessories

Once the mechanicals are in place, consider adding accessories to complete your 4×4 build:

• Roll cage and roof: Essential for safety in off-road conditions.
• LED light bars: Provide improved visibility during dusk or trail rides.
• Winch system: Can help you self-recover if you get stuck.
• Bucket seats with harnesses: Improve safety and comfort in rough terrain.

Important Tips and Precautions

Before starting your conversion project, keep these key points in mind:

• Check local laws: Many regions regulate custom UTVs and modified golf carts. You may need registration or off-road permits.
• Consider a donor vehicle: Using an old ATV or side-by-side as a parts donor can save time and money.
• Balance weight distribution: Battery packs, motors, and accessories add weight. Ensure proper balance to avoid handling issues.
• Professional help: If unsure, consult with a custom cart builder or off-road mechanic for critical tasks.

Conclusion

Converting a standard electric golf cart into a 4×4 side by side is an ambitious but rewarding project. It requires time, mechanical skill, and careful planning, but the result is a highly capable off-road machine customized to your needs. Whether you're upgrading for utility, recreation, or rugged terrain, your new build can go far beyond the green.