A Walk through guide on how I converted a 1980 Reproduction metal pedal car into an electric power wheels

Step 1: Sourcing Parts

I found the pedal car in pretty good shape for $100

I then found a non working yamaha raptor power wheels for parts. $FREE

The rest was stuff I had around the shop or bought locally for pretty cheap not all build will be the same.

Step 2: Testing the Wiring and Motors

After pulling the entire wiring harness out of my donor power wheels I needed to test why it was not working.

At this point I found two reason

First the pedal was rusted and one of the pins was not making contact in the switch

Second they had previously changed the end to use with an after market battery and the splicing was loose in the crimp connector.

After all of this was fixed and bench tested I was able to get Direction (FORWARD)(REVERSE) Speed (HIGH)(LOW)

I added a coupe short videos of the progress

Step 3: Adding the Motor

I have to apologize but I do not have any footage or video of this step.

The process was:

first cutting the original pedal car axle out of the way.
Sliding the solid axle through the motor and welding back into the original configuration
Building a metal cog for the plastic hub of the power wheels motor to sit in
welding the cog into place.
welding a few motor supports

Step 4: High Low Wiring Issues

I made a few simple video of the basics of how the wiring of a power wheels works.

Learning a ton myself in this process and some oversight on my part in the build.

I hope the video helps explain my issue and how I have completely lost my low gear in this build.

Any questions please comment I will be happy to answer anything I can.

Step 5: Test Run

I tossed the harness together and place the battery on the seat just to test everything was moving and rolling smooth.

Step 6: Wiring Layout and Test Fitting the Battery

Here was just a quick layout of the harness and trying to see how much and what else was needed in moving the battery to the front supports.

Step 7: Building Shaping a Floor Pan

All this is a custom build and using the tools I have on hand this was the best I could come up with.

Using a jigsaw a 4x4 and hammer here is the out come.

Step 8: Test Fitting Height and Final Placement of the Floor Pan

Brought my little man out to help get an idea of placement.

After checking height I drilled and added hardware.

Step 9: Covering in Undercoating

Step 10: Switch Box

Took some metal bent to a 90 and cut the holes to fit the switches.

Simple design and worked great painted black and fit perfect

Step 11: Finishing Touches

Here I ran the harness zip tied hot glued and secured everything to the best I could

I built a wooden platform for the pedal and attached it with hot glue I do not expect for this to last or be permanent fix but I wanted it to also be adjustable.