Ultimate Razor Dune Buggy Modification! Sleeper Build

Jtroy

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Hello DIY,

After monitoring the forums for years, and getting a lot of inspiration, I finally get to contribute!

I picked up a junk razor dune buggy for $30 off Craigslist about 6 months ago and have been slowly working on it since then. My goal was to maintain the stock appearance, keep all the chain guards, switch to pedal throttle and brake controls, change the wheels, and upgrade to 48v.

To accomplish this, I modified the frame to accept a custom underfloor mount battery box and installed a custom 48v headway 38120 battery pack with an 80 amp BMS. Added a mounting plate behind the seat to mount the BMS, and throttle to keep them out of sight. I then installed a 48v brushless motor and controller. For the motor, I made a custom adapter plate to maintain the factory chain tensioner. I also made custom brake and throttle pedals. Lastly I used razor e300 scooter wheels with custom hubs.

There were many more small modifications that went into this, and in the end, I am really happy with the fit and finish . I think I met my initial design goals, let me know what you guys think.
 

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Jtroy

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I used the 80 amp version of this BMS and this motor setup.
 

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Sinakhe

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any link or parts for the custom hub to fit the e300 wheels? I’m still new to modifying the razor dune buggy. Anything will be appreciated. Thanks
 

mlw19mlw91

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I'm also looking for the custom hub. On the Facebook group modified razors it's been said that you basically use a sprocket mount to do this
 

Jtroy

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I’m not sure about the Facebook group post, can you link the post? As for the hubs, I built them from scratch on a lathe. That was the only option I could find and they came out perfect.
 

Jtroy

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I see, that was not what I did… looks too flimsy. The cart goes 30mph in the highest motor speed depending on which sprocket setup I use and I personally wouldn’t trust that. I started with 1.5” solid bar stock and made the hub plates from 3/16 plate if memory serves. Then welded it all up and cut the key way.
 

marcleman

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How fast does this thing get?
Hello DIY,

After monitoring the forums for years, and getting a lot of inspiration, I finally get to contribute!

I picked up a junk razor dune buggy for $30 off Craigslist about 6 months ago and have been slowly working on it since then. My goal was to maintain the stock appearance, keep all the chain guards, switch to pedal throttle and brake controls, change the wheels, and upgrade to 48v.

To accomplish this, I modified the frame to accept a custom underfloor mount battery box and installed a custom 48v headway 38120 battery pack with an 80 amp BMS. Added a mounting plate behind the seat to mount the BMS, and throttle to keep them out of sight. I then installed a 48v brushless motor and controller. For the motor, I made a custom adapter plate to maintain the factory chain tensioner. I also made custom brake and throttle pedals. Lastly I used razor e300 scooter wheels with custom hubs.

There were many more small modifications that went into this, and in the end, I am really happy with the fit and finish . I think I met my initial design goals, let me know what you guys think.
 
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