RZR 36V ESC, lighting, strobe, etc - DONE!

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RZR 36V ESC, lighting, strobe, etc - DONE!

Post by toycrusher »

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Sooo, this is yet another project that will keep evolving and never be "finished" :roll: . Picked it up not running too well for a great price. Installed a bushing in the shifter above the rocker switch to get reverse back. Stock circuit board was stuck in slow. I assume it has the "old" 250w motors because it still had the old circuit board. I gutted it for a relay harness, simple, no soft start, so far no problems.
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It has become my son's favorite ride and I like the seat belts since he is known to throw his baby sister with his crazy driving :o

I'm in the process of adding lights currently. I may overvolt later and I'm seriously considering adding a winch since it has so much space up front.
Last edited by toycrusher on Fri Mar 20, 2015 8:35 am, edited 4 times in total.


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Re: Never-Dull RZR

Post by toycrusher »

Eagle Eye headlights

You have to love the fact that Peg Perego puts adhesive back reflectors behind every lense! :D
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Last edited by toycrusher on Tue Oct 22, 2013 2:41 pm, edited 3 times in total.
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Re: Never-Dull RZR

Post by toycrusher »

LED strip lights
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Last edited by toycrusher on Tue Oct 22, 2013 2:40 pm, edited 1 time in total.
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Re: Never-Dull RZR

Post by shardian »

Oh wow, two eagle eyes per lens? That is some serious lightage!
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Re: Never-Dull RZR

Post by Sum Ting Wong »

Lookin nice!
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Re: Never-Dull RZR

Post by toycrusher »

I mounted the switches by the cup holders. I also added red glow lighting in the footwell area. I'll clean up the messy wiring once I'm done adding the roll bar lights and full underglow lighting with remote control.
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Re: Never-Dull RZR

Post by ccsurep »

I'm liking these rzrs, I need to find one fast, and cheap. Nice build. We need more pics of motors, wiring. Also video :) . Looks good
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Re: Never-Dull RZR

Post by toycrusher »

Yeah, they had never really gotten my attention until I picked this one up. Now my son won't hardly touch his other rides, even the super power he won't hardly drive! It's pretty quick wired direct at 24v, 7-8 mph with fully charged battery, and it will run a pretty solid 8-10 miles on a single charge with a stock battery.

We just took it on our first couple mile night jog and I have to say it came out better than I expected! :D The eagle eye leds are pretty decent and the tail lights look like high-end auto LED taillights from a short distance. I'm having trouble with my roll bar lights. I'm using CREE LED chips like you find in high-end flashlights, but I just can't get the solder to stick to the aluminum chip!!! :x :x :x :evil: Anyone have any ideas?
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Re: Never-Dull RZR

Post by toycrusher »

Started working on my roll bar lights. I'm using a batch of three CREE LED's that are commonly found in hi-powered flashlights. Getting the wires soldered proved to be a bit of a pain. I hot glued them to the stock reflector and then filled the housing with foil for a bit extra light. They turned out to be quite bright! :D
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They are 3.7 volts max a piece so I wired them in series and used one of these voltage regulators to turn the power down where I needed it. Just a tip, if your color blind and reverse the input polarity, it goes up in smoke :x
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Re: Never-Dull RZR

Post by toycrusher »

Another "bright idea" may have just caused me some trouble. These CREE chips can pull over an amp a piece! I just wired three in series and lets just say, THEY GET HOT!!! :o

If i happen to melt down the fog light assemblies, look out for my WTB ad for another pair :roll: :lol: :lol: :twisted:
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Re: Never-Dull RZR

Post by bruces_eviltwin »

has your wife eve accused you of over doing things? ;) just a hunch
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Re: Never-Dull RZR

Post by toycrusher »

Got it all wired up and took it out for a test ride.
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Unfortunately the fun was short lived, in less than 5 minutes one of my LED arrays quit and a couple minutes later one led in my other array went dim. :cry:
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Re: Never-Dull RZR

Post by cheapjeeps »

if youre not breaking stuff youre not doing it right. i bet those eagle eyes are still working perfect. ive used them a few times now and im pretty impressed, especially for what they cost.
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

Since this is my boy's ride of choice when we do our several mile night runs, I figured it would be important to make it less-likely that we all get run over by a driver not paying attention. I took some cheesy strobe lights off ebay, gutted them and replaced them with some brighter red and blue leds. Then I used a better strobe controller also off ebay with probably a dozen strobe options.
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Re: Never-Dull RZR off-highway patrol...

Post by cheapjeeps »

the strobes look great! ive used these and they are cheap and very bright only issue is only 2 different strobe options and shipping from china takes forever: http://www.ebay.com/itm/251362456997?ss ... 1423.l2661
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

Yeah, that's basically what I started with. I took out the led panel and put some brighter led strips inside. I'm going to add some more to the ride but unfortunately I too have about a month wait for the next batch to arrive :x :(
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

My high-powered LED roll bar lights were a bust :( so I've swapped them with some led discs instead. Went warm-white for hopefully better range. I've also got in my light bars to convert to more cop lights :D :roll:
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Re: Never-Dull RZR off-highway patrol...

Post by taz11 »

bust ?:cry: :cry: :cry: :cry: :cry: ....Smoke? :P


On a brighter note, where did you get those terminal strips that you used under the seat? (a few posts back next to the battery)
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Re: Never-Dull RZR off-highway patrol...

Post by iDz Bowl »

Looking great!
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

They are marine terminal blocks. They come in a 12 terminal length and I just cut them to the size I want. Some of my guys can wire them really neat and clean, all my stuff ends up looking like spaghetti :x
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Re: Never-Dull RZR off-highway patrol...

Post by cheapjeeps »

Uh oh. look what i just got for FREE! came with battery and charger. works in both speeds forward, no reverse for some reason. Was listed on craigslist as kids battery jeep.
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

Sometimes you just have to slap yourself in the forehead :x

I had been really frustrated with my roll bar lights. My CREE LED chips melted down, I replaced them with bigger discs, and they wouldn't work right. They would turn on for about a minute, then go dim or turn off. I checked connections, replaced my switches, which only sorta helped for a couple more minutes. When I would fire up the headlights the roll bar lights would go out.

Anyway, after several more hours of use with non-functioning roll bar lights :cry: , I noticed the eagle eye headlights were starting to get a bit dim. I pulled the battery, charged it up, and what do you know? These things are blinding! I had to dust off my "noob" cap, put it on and stand facing the corner for a few hours to atone for the time I had wasted :x :roll:
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

Turns out plastic wheels aren't the best choice for jumping off 8" curbs with a payload of 120+lbs of neighbor kids repeatedly for hours on end...
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DOH! :x :x :x

Fortunately Jonesee came to the rescue with a nearly new rear tire. I let my 4-yr old turn the wrenches to change it and we were back in business :D
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Re: Never-Dull RZR off-highway patrol...

Post by CJB »

For your rollbar LEDs, those do get super hot. They need a heat sink. I'm 99% sure they're on an aluminum-clad PCB, so if you cut a chunk of metal (on the thicker side - 1/8" or better) and secure the LED boards to it with some thermally conductive adhesive you'll get much better performance.
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

CJB wrote:For your rollbar LEDs, those do get super hot. They need a heat sink. I'm 99% sure they're on an aluminum-clad PCB, so if you cut a chunk of metal (on the thicker side - 1/8" or better) and secure the LED boards to it with some thermally conductive adhesive you'll get much better performance.
Yup, that would have saved them. I discovered that making high-powered LED lights yourself is waaay too much work and money. What I have in there now is a 44-LED array on an aluminum disc. It works nicely but not much range. Next project I do I will probably just use some of these.

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or these

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Re: Never-Dull RZR off-highway patrol...

Post by houstonbudman »

I have a RZR that I will be adding lights to. What is the wattage of the Eagle Eye lights you use. I have seen them in 3W, 9W and 10W. How much heat to they produce and should there be a concern with using them behind plastic lenses. Also why do you use the LED strip lights in the tail lights instead of the Eagle Eye lights. Thanks,
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Re: Never-Dull RZR off-highway patrol...

Post by jonesee »

glad to see you got the RZR up and running again. :D

As I sit here soldering up led lights looking out the window at over 120 inches worth of snow :x :x

my kids and I are going nuts this winter :( :(

So your Highway Patrol RZR project is done for awhile?
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

houstonbudman wrote:I have a RZR that I will be adding lights to. What is the wattage of the Eagle Eye lights you use. I have seen them in 3W, 9W and 10W. How much heat to they produce and should there be a concern with using them behind plastic lenses. Also why do you use the LED strip lights in the tail lights instead of the Eagle Eye lights. Thanks,
The eagle eyes don't pull even a fraction of an amp. 22ga wire is plenty thick for a whole array of them. They run very cool. Another member here did some tests and has come to the conclusion that the 3w, 9w, 12w eagle eyes are all the same light just rated differently (or incorrectly). From my experience, I completely agree with him.

For the tail lights I used the strips because they are quite bright, cheaper, and look cooler in my nearly-humble opinion... 8-)
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

jonesee wrote:glad to see you got the RZR up and running again. :D

As I sit here soldering up led lights looking out the window at over 120 inches worth of snow :x :x

my kids and I are going nuts this winter :( :(

Brrrr... :!: We had a record cold winter too but that's not saying much.
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A mini ice storm. Not a big deal but we've only had one about 4 times in the last 30 years!
So your Highway Patrol RZR project is done for awhile?
Not even close! Well, sorta. I've got more red/blue strobe lights to install I just haven't gotten around to it. I'm going to add some underglow to it, someday... I also want to eventually either upgrade to the newer 350watt motors, or some banebot 775's if they will fit with the Peg box (haven't researched that yet) and overvolt them to 30v or so.

I'm not big on "completing" projects. I usually stop about 95% of the way :x I do have definite plans to wrap up my 6x6 project (though it may be my baby girl's ride if my boy is too big by then! :x :x :x ). I haven't been able to get my buddy with the tig welder to finish my front suspension. It's tough to negotiate when you aren't a paying customer :lol: :lol: :lol:
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

And it's back under the knife... :o

Swapping out my really messy pair of relays for a twin DPDT auto hi/low relay setup. Also continuing where I left off with police lighting :twisted:
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Re: Never-Dull RZR off-highway patrol...

Post by jonesee »

great job coming up with this setup!

so are you activating the 12 volt relay coils on 24 volts or are you using a in line resistor?

cant wait to see the light upgrades :mrgreen:
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

jonesee wrote:great job coming up with this setup!

so are you activating the 12 volt relay coils on 24 volts or are you using a in line resistor?

cant wait to see the light upgrades :mrgreen:
I am using 24v relays so no need to mess with resistors. :D They were the same price as the 12v relays (ebay, about $8 ea).
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

Ok, ever have one of those moments where you really start questioning your own abilities? I did all the wiring in my head, then sketched it on paper. I traced power flow a few times, it worked out every time. It was late so I did the wiring install in the dark. Connect a battery, and the stupid thing only works with the shifter in reverse, and one wheel spins forward and the other backward. I swap the motor leads around, and SAME THING! :x :evil: It was even later, so I gave up in frustration.

I came back a few days later (in the day light), check my wires over again, do my motor leads again, didn't change anything and now it works like it should in high/low but still had one wheel forward and the other reverse. I checked the Peg diagram for the 10th time and realized it must be incorrect. I swapped around my motor leads again and FINALLY! Success! :D I still have no clue why it was messing with me the first night.

I also wired in the factory speedo/battery gauge which really is a nice feature. We ran it around for about a mile and it's really nice to have the 2 speeds, back :) With the thing running again, I've turned my attention back to my strobe lighting and hope to put it back on the "semi done" list of rides again.
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boostedride
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Re: Never-Dull RZR off-highway patrol...

Post by boostedride »

toycrusher, i like the lights you did on the rzr so i had to try it myself :)

Image
Image
Image

have single led for the tail like which will work fine but like your led strip lights better.
Last edited by boostedride on Thu Jul 03, 2014 8:36 am, edited 1 time in total.
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Re: Never-Dull RZR off-highway patrol...

Post by toycrusher »

Just realized I never posted my wiring diagram. Here are two, one with two relays and another utilizing the factory shift switch for fwd/reverse duties.
Peg hi-low auto pedal dbl dpdt jpg.jpg
Peg hi-low auto pedal -b.jpg
Last edited by toycrusher on Fri Aug 29, 2014 8:45 am, edited 1 time in total.
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Re: Never-Dull RZR off-highway patrol... 36V ESC

Post by toycrusher »

And I'm moving forward with more mods, 36V ESC this time :twisted:

I started with moving to the 350W motors which I'm starting to really love :twisted: but I made an interesting discovery. I'm surely not the first to have figured this out, but I may be the first to take comparison photos :lol:

The RZR was most certainly originally designed for the larger superpower motors. The shape is a perfect fit and even the axle tube has a sleeve to adapt from the 3/4" superpower shaft to the smaller shaft it actually left the factory with. They had to add some molding to the housing to retain the smaller gearboxes but it can all be cut out fairly easily it looks like.
2015-01-04 16.49.39.jpg
2015-01-04 16.49.57.jpg
plastic molding that would need to be hacked up and removed. Also the axle reducer sleeve
plastic molding that would need to be hacked up and removed. Also the axle reducer sleeve
Sooo.... do I hack it up and install superpower wheels? :?: :twisted: :roll:
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Re: Never-Dull RZR off-highway patrol... 36V ESC

Post by SigEp »

Well, my son is finally big enough to drive our Rzr. I found a mint (newer) silver rzr around Christmastime so we flipped our red one and I'm looking to mod the silver one instead. For now, the stock speed is plenty fast and my son is able to get it sideways.

My plan is headlights/taillights, bumper/rollbar lights, underglow, and possible strobes. A couple questions:

1. Is there a reason you didn't use the Eagle Eyes in the bumper and rollbar lights? Is it because they have a bolt that would have stuck out? I'm wondering if that can be modified or cut some somehow... I know you mentioned that the 3, 6, 9w are all the same so I guess just go with 3w since those are the cheapest?
2. On the LED tail light strips, did you go with red LEDs or were white ok with the red light covers? I found in our Firetruck build that the white LEDs can still show white even through the red lens and red LEDs really enhanced the red color.
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Re: Never-Dull RZR off-highway patrol... 36V ESC

Post by toycrusher »

SigEp wrote:Well, my son is finally big enough to drive our Rzr. I found a mint (newer) silver rzr around Christmastime so we flipped our red one and I'm looking to mod the silver one instead. For now, the stock speed is plenty fast and my son is able to get it sideways.

My plan is headlights/taillights, bumper/rollbar lights, underglow, and possible strobes. A couple questions:

1. Is there a reason you didn't use the Eagle Eyes in the bumper and rollbar lights? Is it because they have a bolt that would have stuck out? I'm wondering if that can be modified or cut some somehow... I know you mentioned that the 3, 6, 9w are all the same so I guess just go with 3w since those are the cheapest?
2. On the LED tail light strips, did you go with red LEDs or were white ok with the red light covers? I found in our Firetruck build that the white LEDs can still show white even through the red lens and red LEDs really enhanced the red color.
I did use eagle eyes for the headlights. The stud is what has kept me from using them in many locations like the rollbar lights, though you can cut the threaded part off and just re-solder the wires back on. As far as the light strips, yes they are red. I've found the same thing, the lenses just don't tint the light as much as you would think. Maybe it's a different plastic then what is used in real cars?
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Re: Never-Dull RZR off-highway patrol... 36V ESC

Post by SigEp »

I found these that look interesting. I ordered some for the bumper and rollbar lights:

http://www.ebay.com/itm/171597973993

I'm going to go with the bolt/stud style ones for the headlights so they will point nice and straight.
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Re: Never-Dull RZR off-highway patrol... 36V ESC

Post by toycrusher »

So I played with swapping to SuperPower wheels... I really didn't like the way it looked personally. Then there was the whole issue of the front spindle not being long enough, and that definitely killed the deal...
2015-01-07 21.42.53.jpg
2015-01-07 21.43.09.jpg
2015-01-07 21.43.27.jpg
2015-01-07 21.43.48.jpg
I'm not ruling out wasting money on some aggressive Ag tires in the future though... :twisted:
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Re: Never-Dull RZR off-highway patrol... 36V ESC

Post by toycrusher »

Finally got back into my ESC install. I also changed up and added a dozen light bars for my police strobe. Didn't come out too bad in my opinion ;) :lol: :roll:
Pedal install variable and brake
Pedal install variable and brake
ESC components
ESC components
Key Switch and 36v voltmeter
Key Switch and 36v voltmeter
Roll bar net from Gaucho
Roll bar net from Gaucho
Should I keep it?
Should I keep it?
Light bars
Light bars
Light bars
Light bars
Four mounted on rear bar too
Four mounted on rear bar too
I have to connect it all up still. Next stage, If I get there, will be superpower gearboxes and Ag tires :twisted:
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grndamgt4
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Re: Never-Dull RZR

Post by grndamgt4 »

toycrusher wrote:Eagle Eye headlights

You have to love the fact that Peg Perego puts adhesive back reflectors behind every lense! :D
20131017_222343m.jpg
20131017_222843m.jpg
20131017_225553m.jpg
20131017_225547m.jpg

How did you get the light covers to fit over the LED's?
I have the 12 volt razr and the eagle eye LED's have a gap (that I guess is for a car mounting option) that makes them stick out to far to fit the headlight cover back on.
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Re: Never-Dull RZR off-highway patrol... 36V ESC

Post by toycrusher »

I haven't had a chance to play with a 12v version, so I can't exactly answer your question. On the 24v version, there is TONS of room for the Eagle Eyes :D

I liked another members roll bar padding so I roughly copied him (Did not come out as nice though :cry: :roll: :lol: ) as well as added a Gaucho rear net. I had to notch a pvc pipe to make the lower mounting base for the net. After that, some 1-1/2" pipe insulation and a couple rolls of duct tape. Took a ton of trimming for my red/blue strobe lights, but now that it's done I like it :D
2015-02-19 20.59.16.jpg
2015-02-19 21.26.19.jpg
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Re: RZR 36V ESC, lighting, strobe, etc - DONE!

Post by toycrusher »

Finally had to break out the "Big Guns" to get this one done... :lol:
I gave him a tool kit and now all I hear is, "Ok, dad, what do I do dad? Which tool do I use dad?" My daughter never asks, she just swipes a tool and goes to town on whatever's nearby :-D
I gave him a tool kit and now all I hear is, "Ok, dad, what do I do dad? Which tool do I use dad?" My daughter never asks, she just swipes a tool and goes to town on whatever's nearby :-D
Key On
Key On
Lights on
Lights on
Lights on
Lights on
Strobe only
Strobe only
All lights on
All lights on
2015-03-17 05.31.44.jpg
I ended up going with three Gruber 12ah batteries. I wanted 18AH but I just couldn't fit three nicely anywhere, well, other than in the nose but I didn't really feel like going there. This will likely continue to be a mud machine and the weight is better on the driven wheels.

If we need a laugh, when I first hooked it up, I had wired my reverse relay as a hi-lo relay :roll: Doh! :x I like the roll bar padded and wrapped in duct tape, but we'll see how quickly it turns nasty. Is there another good alternative to duct tape?

I may later add a 48v "Turbo" button, gonna have to hit up CJB for a turbo timer there. In any case, it's done for now. Only major changes I see coming up is a swap to Tiller AG tires and gen1 superpower gearboxes. I'll post more when I get there ;)
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Re: RZR 36V ESC, lighting, strobe, etc - DONE!

Post by toycrusher »

Fun modding week. Rzr dropped to one wheel drive. Went to troubleshoot, found melted relay. Replaced relay, still no-go. Pulled wheel and gearbox, motor melted down, fan blades missing and all :o

Swapped to a spare (used) motor, pushed the gas and the stupid thing caught fire! :shock:

Swapped to a 2nd spare and it's up and going again. Why did it all die? Well, it had something to do with my son driving through 12" deep mud... repeatedly... :x
VZM.IMG_20151026_102405.jpg
2015-10-26 11.37.03.jpg
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Re: RZR 36V ESC, lighting, strobe, etc - DONE!

Post by toycrusher »

I just melted down a 3rd motor in two days, flames and all :evil: :evil: :evil:

Any ideas as to why? It's run easily 30 miles in 2-mile trips since I put it together, and now the motors decide they can't handle 36v? The particular gearbox is a little tighter than the other, could that be my issue?
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Re: RZR 36V ESC, lighting, strobe, etc - DONE!

Post by sall »

No idea man! Well perhaps a massive amount of resistance somewhere in your wiring.

... but high power lighting builds are the star fish. Yes, you need heatsinking and drive them at an appropriate current! You also need a constant current driver not a simple resistor. These are what I put in my RC Jeep which I haven't posted abuild log for yet...

Luxeon PC Amber Tri-star for park lamps in motorcycle turn housing. Ran by dual intensity constant current driver. These PC ambers are a bit expensive for this application but had them from an old vehicle project. Might as well had used them for something.

Image
Image
Image

Stop/Tail/Turns w/ Cree XP-E and dual intensity constant current driver. Cree XP-E are ~$1 a piece.
Image
Image



Constant current drivers are a simple LM317 setup. Cost about $1 per driver for parts. Yeah more expensive than running a $1 eagle eye but a thousand times better. Eagles eyes get hot too. The lighting setup on the RC PW is killer. More than mentioned here...
Last edited by sall on Fri Oct 30, 2015 6:49 pm, edited 5 times in total.
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Re: RZR 36V ESC, lighting, strobe, etc - DONE!

Post by toycrusher »

Well my 850 quad sacrificed a gearbox and motor to get the rzr on the road again. That one gearbox was just waaay too tight and burned up the three motors. Eventually I'll open it up to find the problem
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Re: RZR 36V ESC, lighting, strobe, etc - DONE!

Post by toycrusher »

Man, these kids know how to find weaknesses in the Rzr gearbox! They blew ANOTHER driver that is not available separate from the complete gearbox :evil: :(
2015-12-06 15.45.24.jpg
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Re: RZR 36V ESC, lighting, strobe, etc - DONE!

Post by toycrusher »

What the heck!!! :evil: :evil: :evil:

These kids have broken 3 gearboxes and burned up 4 motors in like 3 hours ride time! :shock: :evil:

What's going on? Best I can tell, I have ever the slightest bend in my axle. I have power wheels with axles shaped like a "v" and it didn't seem to bother them. Could that really be my problem?
IMG_20151221_112458.jpg
"I'm not nuts, I prefer to be called an enthusiast! "

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