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Old 09-22-2017, 11:06 AM
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Default Electric Badger 450 Mini Bike

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)

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Old 09-28-2017, 07:55 AM
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I got her out & let Desteny ride 'er for the first time

She did real good

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Old 06-24-2019, 01:36 PM
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Default Upgrading to a 48V 1,000W system

The kids are gettin' bigger.

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

Even still has all of the original badging & stickers
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Old 06-24-2019, 09:05 PM
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Old 06-25-2019, 12:05 AM
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Thats a nice little lectric bike!
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Old 06-25-2019, 06:34 AM
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First thing we gotta do is take it apart or "tear it down"

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Old 06-26-2019, 06:03 AM
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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
...so, on reassembly, I can put 'em back the same way

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

Yup, looks good
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Old 06-26-2019, 08:13 AM
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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)
...it's a nice blue metallic which then shifts to purple

I was thinkin'
...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
...so, if we do this it will giv'er a fresh look & also seal 'er up good too.

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.
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Old 06-26-2019, 08:17 AM
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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.
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Old 06-26-2019, 10:11 AM
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Quote:
Originally Posted by JTSpeedDemon View Post
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
Actually, I have not owned a car since like ~1991

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

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

FYI:
My tow truck has an intercooled turbo diesel
…& I have to admit, I love to hear that turbo sing
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Old 06-26-2019, 03:07 PM
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Yeah my brain slipped up there. I'm not surprised that all your karts/minibikes are electric.
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Old 06-27-2019, 06:13 AM
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Here is how she looks.

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

Here is a video of progress. (so far)


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

Gotta work on gettin' 'er to smooth out (too much orange peel)
...but, still a very, very unique look.
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Old 06-30-2019, 07:01 AM
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Some more pics

I didn't mask anything & just sprayed the color shifting pearl/clear right over the decals too
...it didn't seem to effect them much
(just sealed 'em up with the rest of the bike)
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Old 07-02-2019, 06:09 AM
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Default Battery Box

I got the wheels on & parked 'er out in the sunshine
...while working on the battery box (looks so kool from different angles)

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

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

A little measurin' & markin" & cuttin'
…& then, some roundin' & smoothin'
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Old 07-02-2019, 09:44 AM
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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

I figured I could tackle these bends.

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

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

Yup, that'll work
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Old 07-02-2019, 10:54 AM
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Default Re-purposing the old battery box

Now, lets open up the original/plastic battery box
…& see what we got to work with

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


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

Well, 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.

Hmmm, seems to fit & looks kool
...but, this handle may have to go
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Old 07-02-2019, 11:50 AM
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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

So yup, the handle has gotta go

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)
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Old 07-02-2019, 01:08 PM
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Default Mounting the side panels

How are we gonna mount the old battery box "side panels" to the new battery box?

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"
...so, not something kind of "permanent" like two sided tape
...but, also something a little stronger than just "stuck on" with Velcro


Maybe we can "stud it"

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)

Yea, that'll work :
...good-n-solid & easily removable
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  #19  
Old 07-03-2019, 12:26 AM
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Nice and clean work FA. I love watching what you do
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Old 07-03-2019, 11:17 AM
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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

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.

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

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

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

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

Here is a video of progress so far

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