06-17-2018, 10:06 PM | #1 |
Not Yet Wild
Join Date: Sep 2017
Posts: 12
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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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06-18-2018, 04:41 AM | #2 |
Gone Wild
Join Date: May 2013
Location: Pendelton NY ( F cuomo)
Posts: 923
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Re: Bad Boy Buggy conversion and rebuild...
this would be interesting to many i am sure
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06-18-2018, 06:57 AM | #3 |
Gone Wild
Join Date: Oct 2012
Location: Southwestern Pa.
Posts: 6,204
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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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06-18-2018, 09:02 AM | #4 |
Voltaholic
Join Date: Dec 2013
Location: Close to Navasota Texas
Posts: 934
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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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06-19-2018, 10:51 AM | #5 |
Not Yet Wild
Join Date: Sep 2017
Posts: 12
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Re: Bad Boy Buggy conversion and rebuild...
It is a Dana and I have heard of that mod. On my "post phase one" list...
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06-19-2018, 10:59 AM | #6 | |
Gone Wild
Join Date: Oct 2012
Location: Southwestern Pa.
Posts: 6,204
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Re: Bad Boy Buggy conversion and rebuild...
Quote:
I'm not sure if the factory EZ-GO limited slip works in forward and reverse. FWIW |
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06-23-2018, 05:03 AM | #7 |
Not Yet Wild
Join Date: Sep 2017
Posts: 12
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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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06-23-2018, 05:18 AM | #8 |
Not Yet Wild
Join Date: Sep 2017
Posts: 12
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Re: Bad Boy Buggy conversion and rebuild...
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08-08-2018, 12:22 PM | #9 |
Not Yet Wild
Join Date: Sep 2017
Posts: 12
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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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08-08-2018, 02:21 PM | #10 |
Gone Wild
Join Date: Oct 2012
Location: Southwestern Pa.
Posts: 6,204
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Re: Bad Boy Buggy conversion and rebuild...
Your build looks great!! Nice work!!
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