Help! I have a crack in the plastic body of my golf cart

My beloved 1998 Club Car DS has developed some nasty cracks in its plastic body. It’s more than just an eyesore; I’m worried about the structural integrity. Has anyone tackled this successfully? Desperate for some solid advice.


Oh I’ve been there with my EZGO golf cart. What really saved the day for me was plastic welding. It’s a bit of a task, but the results were impressive

Solutions that Worked for Users

SolutionUsers Who Found SuccessApprox. Cost (USD)Approx. Time Needed (Minutes)
Plastic Welding with a Soldering Iron220-5030-60
Using JB Weld Plastic Weld Epoxy210-3020-40
Sanding and High Build Primer115-3545-60


  • Visible cracks in the plastic body of the golf cart.
  • Potential weakening of the cart’s structural integrity.

Possible Causes

  • Regular wear and tear.
  • Exposure to harsh environmental conditions.
  • Physical impact or stress.

Solutions that Worked

  1. Plastic Welding with a Soldering Iron
    • What I Did: Used a soldering iron to weld the plastic, adding material for bonding and filling.
    • Outcome: The cracks were effectively repaired and the body’s integrity restored.
    • Personal Experience: I found that using a soldering iron for plastic welding was effective. It’s important to be patient and work carefully to ensure a strong bond.
    • Estimated Cost: $20-50
    • Time Needed: 30-60 minutes
    • Steps:
      1. Clean the cracked area thoroughly with soap and water, then dry it.
      2. Heat the soldering iron. While waiting, cut a piece of similar plastic to use as a filler.
      3. Gently melt the edges of the crack with the soldering iron.
      4. Press the filler plastic into the crack, melting it with the iron to bond it.
      5. Smooth out the repair as much as possible while it’s still warm.
      6. Allow the repair to cool and harden for at least an hour.
      7. Sand the repaired area with fine-grit sandpaper until it’s smooth.
      8. If desired, apply paint to match the original color.
    • Expert Tip: Always work in a well-ventilated area and wear protective gloves. Practice on a scrap piece of plastic first if you’re new to plastic welding.
  2. Using JB Weld Plastic Weld Epoxy
    • What I Did: Applied JB Weld plastic weld epoxy as a filler.
    • Outcome: The cracks were filled, and the repair was strong and sandable.
    • Personal Experience: This method provided a durable repair that was easy to sand and finish.
    • Estimated Cost: $10-30
    • Time Needed: 20-40 minutes
    • Steps:
      1. Clean the area around the crack with a degreaser and let it dry.
      2. Prepare the JB Weld plastic weld epoxy as per the instructions.
      3. Apply the epoxy carefully, filling the crack completely.
      4. Use a putty knife or similar tool to smooth out the epoxy.
      5. Allow the epoxy to cure for the time specified by the manufacturer.
      6. Once cured, sand the area with fine-grit sandpaper until smooth.
      7. Clean the sanded area and apply paint if necessary.
    • Expert Tip: For deeper cracks, apply the epoxy in layers, allowing each layer to cure before applying the next.
  3. Sanding and High Build Primer
    • What I Did: Sanded out the hairline cracks and used a high build primer.
    • Outcome: Minor imperfections were smoothed out, and the surface was prepped for painting.
    • Personal Experience: This method worked well for superficial hairline cracks.
    • Estimated Cost: $15-35
    • Time Needed: 45-60 minutes
    • Steps:
      1. Start with a coarse-grit sandpaper to remove any rough edges around the crack.
      2. Gradually move to finer grits to smooth the area.
      3. Clean the area thoroughly with a tack cloth to remove all dust.
      4. Apply a high build primer to fill in the imperfections.
      5. Allow the primer to dry as per the product instructions.
      6. Sand the primed area with fine-grit sandpaper for a smooth finish.
      7. Clean the area again and apply paint as needed.
    • Expert Tip: Use multiple light coats of primer rather than one heavy coat to avoid drips and runs.


Ernie loves documenting interesting facts about golf.

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