Zerotow Boogie V3 Hull Replacement

Escrito Por: Mark Duyvesteyn
  • Comentários: 0
Zerotow Boogie V3 Hull Replacement

Dificuldade

Moderate

Passos

14

Tempo necessário

1 - 2 hours

Introdução

Follow this guide to perform a hull replacement on a V3 Zerotow Boogie.

    • Remove the battery from the Boogie

    • Place the Boogie on the trolley. This helps support and protect the motor

    • Inflate the Boogies hull to 1-2psi

    • Fully open the zip

    • This guide was photographed outside of a Boogie hull for better angles and lighting.

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    • Remove GPS from back of the control Box.

    • It is held in place with 3M dual lock velcro and can be pulled of with out tools

    • Be careful to no tug on the GPS cable as it is fragile

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    • Use a #1 Phillips screwdriver to loosen the screws and then lift off the case.

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    • Wiggle to top plate from side to side to remove it.

    • The top plate it is not held down with any screws.

    • If the bearings stay on the shafts that is ok, they can be removed later.

    • Do not unplug the top plate.

    • Remove the the extra cable in the slot so you have room to move the top plate to the side.

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    • Use a quality 5mm allen key with a long arm to remove the allen bolt

    • This is done up very tight, an electric impact driver makes this job a lot easier. Remove the bolt completely.

    • If the bolt breaks it can be replaced with a M6 x 35mm tight tensile steel bolt.

    • Use a small flat head screwdriver and hammer to wedge the slot apart slightly. This makes removing the gear from the shaft easier.

    • Leave the screwdriver in place to make reinstallation easier

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    • Remove the Idle gear

    • The idle gear can be lift out with out any tools.

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    • Remove both orange cable guides

    • Remove the tube from the cable guide

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    • Lift away the control PCB and place upside down

    • Do not unplug anything from the control PCB

    • Unscrew the three motor phase cables

    • The cables are different lengths to make reassembly easier. Shortest first, medium then longest.

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    • Lift the three cables and the breather tube though the slot

    • Be careful to not pinch or cut any of the cables - they are easily damaged

    • Once the cables are inside the slot, the motor can be dropped out of the bottom of the Boogie and put to the side.

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    • Unscrew the M4x10 screw using a 3mm allen key

    • The steering motor lifts out of the case and can be put to the side

    • Do not unplug any cables

    • The magnetic disc and encoder on the back of the steering motor is fragile

    • Do not remove the motor from the 3D printed base plate.

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    • Use the supplied tool to loosen the castle nut

    • Remove the nut and fiber washer completly

    • Push the baseplate down out of the Boogie

    • Once the base plate is removed, the hull can be deflated and the control case slid forward and out of the Boogie hull.

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    • The orange spacer ring has been updated to make reassembly easier

    • Remove and discard this spacer ring.

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    • Follow the steps in reverse to reinstall the new hull

    • The new supplied spacer ring gets installed before placing the red fiber washer.

    • The spacer rings isolates the stainless from the aluminum

    • The spacer rings needs to be flush with the case

    • The steering will self calibrate using the limit switches, just make sure that the motor is approximately centered.

Autor(a)

Mark Duyvesteyn

Membro desde: 11/02/26

568 Reputação

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