DIY Go Kart Forum

DIY Go Kart Forum (
-   Mini Bikes, Trikes, and Choppers (
-   -   Electric Badger 450 Mini Bike (

Functional Artist 09-22-2017 11:06 AM

Electric Badger 450 Mini Bike
1 Attachment(s)
It's a Serengetti Motorsport Badger 450 Electric minibike

I bought it new from the 2010 Northern Tool catalog

I used to ride my twins Desteny & Winston around on it when they were little

It's been put away for a while

so, lets get 'er out & brush off the cob webs

It has a 24V 450W electric propulsion system (for now)

Functional Artist 09-28-2017 07:55 AM

I got her out & let Desteny ride 'er for the first time

She did real good :thumbsup:

Functional Artist 06-24-2019 01:36 PM

Upgrading to a 48V 1,000W system
8 Attachment(s)
The kids are gettin' bigger. :smiley_omg:

So, I figured it's time to get our little electric minibike cleaned up
...& also up graded so she goes a bit faster :thumbsup:

Even still has all of the original badging & stickers :2guns:

BigWes 06-24-2019 09:05 PM


landuse 06-25-2019 12:05 AM

Thats a nice little lectric bike!

Functional Artist 06-25-2019 06:34 AM

5 Attachment(s)
First thing we gotta do is take it apart or "tear it down"

Functional Artist 06-26-2019 06:03 AM

9 Attachment(s)
Forgot to mention, before I removed the wheels, I drew up a diagram & took some pics of the location of where the different sized spacers go, on reassembly, I can put 'em back the same way :cool:

Also, before I started the clean up, I "dry fit" the 48V 1,000W motor & chain double check the fit & alignment (just to be sure) :cheers2:

Yup, looks good :wai:

Functional Artist 06-26-2019 08:13 AM

5 Attachment(s)
The original plan was just a good cleanin' but, then I had an idea

Wonder what the "Delta color shifting pearl" would look like, if applied over this dark green metallic?

* When applied over a gloss black background (like on Damien)'s a nice blue metallic which then shifts to purple :2guns:

I was thinkin' :idea2:
...if applied over this dark green
...maybe we'll get a turquoise to (IDK) some different shade of purple

** During cleaning I noticed that this green paint had a lot of flaws & scrapes, if we do this it will giv'er a fresh look & also seal 'er up good too. :thumbsup:

So, after a good top to bottom cleaning I used a scotch bright pad to lightly scuff the entire bike
…& then, hung the frame & gave 'er another good wipe down to remove that dust

*** In the third pic, the fender on the left has already been scuffed

Wasn't really tryin' to remove a lot of material
...just wanted to knock off the shine
...& give the top coat something to grab on to

**** Another experiment
I painted a plastic bottle blue & another purple & will spray a few coats of the color shifting pearls on them, just to see what kind of colors we get. :cheers2:

JTSpeedDemon 06-26-2019 08:17 AM

Kevin, I've got two questions that the whole world wants the answers to:
Do you drive a Tesla or other electric car?
Do you have any gas powered projects???
The answers will solve humanity's problems.

Functional Artist 06-26-2019 10:11 AM


Originally Posted by JTSpeedDemon (Post 526863)
Kevin, I've got two questions that the whole world wants the answers to:
Do you drive a Tesla or other electric car?
Do you have any gas powered projects???
The answers will solve humanity's problems.

Looks like 3 questions :huh:
Actually, I have not owned a car since like ~1991

a Tesla -sadly No (I wish) :drool5:
other electric car - Not yet (probably a future DIY project) :lolgoku:
any gas powered products - Yup, a weed wacker :roflol:

I don't see how it helps with humanity's problems
...but, OK

My tow truck has an intercooled turbo diesel
…& I have to admit, I love to hear that turbo sing :2guns:

JTSpeedDemon 06-26-2019 03:07 PM

Yeah my brain slipped up there. I'm not surprised that all your karts/minibikes are electric.

Functional Artist 06-27-2019 06:13 AM

9 Attachment(s)
Here is how she looks. :thumbsup:

* The sixth pic shows the contrast of before & after paint. :cool:

Here is a video of progress. (so far) :cheers2:

** I noticed that the colors/shades didn't seem to change much
...over the green background instead of black :huh:

Gotta work on gettin' 'er to smooth out (too much orange peel)
...but, still a very, very unique look. :2guns:

Functional Artist 06-30-2019 07:01 AM

5 Attachment(s)
Some more pics :thumbsup:

I didn't mask anything & just sprayed the color shifting pearl/clear right over the decals too didn't seem to effect them much
(just sealed 'em up with the rest of the bike) :2guns:

Functional Artist 07-02-2019 06:09 AM

Battery Box
7 Attachment(s)
I got the wheels on & parked 'er out in the sunshine
...while working on the battery box (looks so kool from different angles) :thumbsup:

To use as a battery box, I had a tray bent up out of ~1/8" steel (~$20.00)
...4" wide (ID.) x 2" tall (sides) x 26" long

I had it done @ my local steel yard
...don't have the equipment to properly bend a long run of 1/8" steel
*Sometimes you gotta "pick your battles" as I probably could have rigged something up to bend it
...but, it wouldn't be easy or very pretty :ack2:

These batteries are ~4" long (4" x 6" = 24")
...but, I had 'em make 'er ~26" long
This way, I would have an extra inch on each end to be able to add retaining tabs :cheers2:

A little measurin' & markin" & cuttin'
…& then, some roundin' & smoothin' :2guns:

Functional Artist 07-02-2019 09:44 AM

6 Attachment(s)
Next, I used a 4" x 4" block of wood as kinda like an anvil to bend the end tabs up.
...a layer of foam helped 'em fit together nice-n-snug :thumbsup:

I figured I could tackle these bends. :cheers2:

After the first bend, I loaded up the (4) batteries double check the "fit"

Then, bent the other side "right on the line"

Yup, that'll work :2guns:

Functional Artist 07-02-2019 10:54 AM

Re-purposing the old battery box
8 Attachment(s)
Now, lets open up the original/plastic battery box
…& see what we got to work with :thumbsup:

The terminals/connections on these old batteries are lookin' kinda crusty :ack2:

The fuse holder & charge port got hot & melted (a long time ago), I installed an "in-line" fuse/holder & external charge port.

Well, :idea2: I'm thinkin' that if we wack off the "bad end"
...maybe we can use this plastic box as a cover to protect the exposed portion of the batteries/tray. :cheers2:

Hmmm, seems to fit & looks kool
...but, this handle may have to go :huh:

Functional Artist 07-02-2019 11:50 AM

9 Attachment(s)
I noticed that if the plastic box is mounted all of the way forward (sorry didn't get a pic) there could be an open area to mount
...a circuit breaker
...the key switch
...& a charge port :thumbsup:

So yup, the handle has gotta go :ack2:

Marked & cut out for spot for the circuit breaker
...then, kinda evenly marked & drilled appropriate sized holes for the key switch & charge port
(used a file to create the notch for the key switch)

Functional Artist 07-02-2019 01:08 PM

Mounting the side panels
10 Attachment(s)
How are we gonna mount the old battery box "side panels" to the new battery box? :idea2:

The batteries fit pretty snug so, there is not much room to have anything inside of the box
(like the ends of screws or the heads of bolts)

I want them to be "removable", not something kind of "permanent" like two sided tape
...but, also something a little stronger than just "stuck on" with Velcro :huh:

Maybe we can "stud it" :thumbsup:

Drilled a couple of holes
...threaded 'em
...ran some misc. 1/4" bolts from the inside to the appropriate length (for some chrome acorn nuts)
...cut the excess off (from the inside of the box)
...smoothed the area
...ground a "notch" (to get better penetration)
…welded the studs (from the inside)
…& then, smoothed the area a little bit (so it can't damage or be abrasive to the sides of the batteries) :cheers2:

Yea, that'll work ::wai:
...good-n-solid & easily removable :2guns:

landuse 07-03-2019 12:26 AM

Nice and clean work FA. I love watching what you do

Functional Artist 07-03-2019 11:17 AM

10 Attachment(s)
This 48V 1,000W speed controller is quite a bit bigger than the 24V 450W speed controller that was on here
…& as such will not fit in the same place as the old one :ack2:

It seems like if it is turned sideways it will fit in the area
...but, then it will be in the way of the motor mount bolts. :huh:

I gently flipped 'er over, to gain a better perspective :cheers2:

Hmmm, maybe we can put 'er up on "stilts" or like raised posts :idea2:

Yup, that'll work
…& the bottom protective cover still fits & clears everything. :2guns:

I also installed the brake lever, cable & caliper
…& the new twist throttle grip :cool:

Here is a video of progress so far :popcorn:

All times are GMT -6. The time now is 09:36 PM.

Powered by vBulletin® Version 3.8.4
Copyright ©2000 - 2020, Jelsoft Enterprises Ltd.