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Old 06-17-2018, 10:06 PM   #1
ejonesie22
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Default Bad Boy Buggy conversion and rebuild...

So after the failure of the second of the original motors after running my 2008 Bad Boy Buggy as a 2 wheel drive after I inherited it a couple of years ago it was time to get away from the always failing Sevcon Controller and the old odd ball other parts they used. After a little research and a few emails with our friend Scotty I sourced from him a whole new system. Using his Solid Sate update kit and a new motor.

So begins making the old buggy essentially a new 2 wheel drive machine with far simpler lay out. I told Scotty I would chronicle the rebuild here. Next week or so I will start and plan on recording all the "prototyping" I will be doing as far as fitting and wiring. I am splitting off all the accessories pieces into their own 12 volt system and changing the lights and all accordingly with leads and such.

Hopefully in the end I can share a blueprint on how to revive these old buggies into something more reliable and still very useful. I have never found that the buggy would have needed 4 wheel drive even if I ever had it, since the front controller was dead when I got it so I see no need to get too complicated.

Anyways check back in as I progress...
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Old 06-18-2018, 04:41 AM   #2
Dennisneri
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Default Re: Bad Boy Buggy conversion and rebuild...

this would be interesting to many i am sure
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Old 06-18-2018, 06:57 AM   #3
DaveTM
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Default Re: Bad Boy Buggy conversion and rebuild...

I can only assume that the BBB's have a Dana rear end. If so, you can install a Plowman's limited slip differential, and have your "new" BBB get just about anywhere it would have gone with the 4 wheel drive.
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Old 06-18-2018, 09:02 AM   #4
Revolution
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Default Re: Bad Boy Buggy conversion and rebuild...

If you want to sell the front end I would be interested. I have been wanting to make my 4x4 BBB 4 wheel steering for a while now LOL!
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Old 06-19-2018, 10:51 AM   #5
ejonesie22
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Default Re: Bad Boy Buggy conversion and rebuild...

Quote:
Originally Posted by DaveTM View Post
I can only assume that the BBB's have a Dana rear end. If so, you can install a Plowman's limited slip differential, and have your "new" BBB get just about anywhere it would have gone with the 4 wheel drive.
It is a Dana and I have heard of that mod. On my "post phase one" list...
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Old 06-19-2018, 10:59 AM   #6
DaveTM
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Default Re: Bad Boy Buggy conversion and rebuild...

Quote:
Originally Posted by ejonesie22 View Post
It is a Dana and I have heard of that mod. On my "post phase one" list...
If you go places where mud and\or snow is....you will appreciate having a limited slip. My new Plowman's works great....in both forward and reverse.

I'm not sure if the factory EZ-GO limited slip works in forward and reverse.

FWIW
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Old 06-23-2018, 05:03 AM   #7
ejonesie22
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Default Re: Bad Boy Buggy conversion and rebuild...

I will write up more details later but here are a few pictures from the project so far. Did the work to date a couple of nights this week. Had to run to farm this weekend to mow and get my heavy gauge crimping tool to build the battery and motor cables.












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Old 06-23-2018, 05:18 AM   #8
ejonesie22
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Default Re: Bad Boy Buggy conversion and rebuild...

Quote:
Originally Posted by Revolution View Post
If you want to sell the front end I would be interested. I have been wanting to make my 4x4 BBB 4 wheel steering for a while now LOL!
May do that. Been looking fir a standard axle lifted front end.
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Old 08-08-2018, 12:22 PM   #9
ejonesie22
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Default Re: Bad Boy Buggy conversion and rebuild...

Ok this is done, and it runs much better except the fact 6 of my batteries of 5 years old and nearly dead. But I recommend the conversion. Photos to follow...
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Old 08-08-2018, 02:21 PM   #10
DaveTM
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Default Re: Bad Boy Buggy conversion and rebuild...

Your build looks great!! Nice work!!
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