We are a team of students from Wichita State University Engineering Department in the Service Learning Class. We are designing this modification and building this car for a young girl 1 1/2 years old. Part of the modification will allow her to use it for many years customizing it to adjust size as she grows. She has Spina Bifida, so we will be doing a few modifications to help her drive the vehicle another way and add some other safety features or beef up the ones that are there. These include:
1. Big Green Round Switch - To accelerate the vehicle via the steering wheel rather than gas pedal
2. Raised Floorboard - We will use foam padding to raise the floor so her feet do not dangle, can be removed as she grows and needs more room
3. Kill Switch - Added to rear of vehicle for parents to easily shut off vehicle immediately
4. Flair - Added stickers fitted to her interests
Step 1: Parts / Tools
(1) $150 Costzon Audi Vehicle - https://www.amazon.com/Costzon-Licensed-Powered-Riding-Vehicle/d
(1) Steering Wheel
(2) Rear Wheels
(2) Front Wheels
(1) Steering Tube
(1) Remote Control (Batteries not included)
(2) Side view mirror
(1) Mp3 cord
3-Year Accident Protection for $22.99*
2-Year Accident Protection for $15.99*
*(May be void after modifications)
(1) Big Green Round Switch
(1) Emergency Shut Off Switch
(1) Roll of 20 Gauge Wire
(4) Small Wire Nut
(3) 3/8" Nut and Bolt
(2) Female Disconnect Terminals
(1) Phillips Screw Driver
(1) Flathead Screw Driver
(1) Electric Drill
(1) Wire Stripper
(1) Socket set w/ Phillips head bit
Step 2: Safety Precautions & Maintenance
Read all instructions carefully and thoroughly before use.
1. Use only under adult supervision and keep small assembly parts away from children to avoid swallowing.
2. The car should be assembled by an adult before use and checked before each use for loose or disconnected assemblies.
3. Use only on flat ground.
4. Only one child at a time in vehicle less than 30 kg.
5. Avoid quickly switching from manual to R/C function.
6. Turn off the car when not in use.
7. Avoid running into things or being near anything sharp that may scratch it.
8. Avoid making contact with the wheels when in use and keep other children a safe distance away.
9. Hold onto the steering wheel tight when in use and use the seat belt.
10. Teach children what all the controls do and how to navigate obstacles.
Battery: 2x6 V 4 Ah rechargeable battery
Load Limit: 30 kgs
1 (slow) 0-2 km/h
2 (middle) 0-3 km/h
3 (high) 0-4 km/h
Play Time : 70-80 minutes
Suitable Age: Up to 7
Product Size: 114x64.5x52.5cm
Charger Voltage: DC 12V
Charge Time: 8-12 hours
R/C or Big Green Button Switch - alternate between R/C use and manual
MP3 Jack - Insert MP3 Player for music
Volume Knob - Turn Volume Up or Down
Voltmeter - Displays power
Power Switch - Turns power on and off to vehicle
Gears - Switch between gears
Step 3: Assembly Instructions
1. Install front wheels by putting washer on the shaft and then wheel until it clicks.
2. Install rear wheels the same as the front but without washer and instead use connecting sleeve and aligning gears until it clicks.
3. Pressing center button on outside of wheel and pulling out allows removal
4. Install steering tube by inserting into gearbox hole from the bottom of the car. Align steering shaft with "U" shape on steering bars that connect to the wheels. Secure in place with screw, lock washer, and nut.
5. Align windshield with the instrument dashboard.
6. Connect dashboard wires to car body.
7. Connect dashboard and windshield aligning with holes on top.
8. Use two 4 x 16 PA screws to connect top of dashboard to car body.
9. Set both batteries in seat compartment under the seat.
10. Lay plastic strip across batteries using rotary knobs to secure the batteries in place.
11. Connect battery to receiver board box.
12. Connect the wire from the steering column to the steering wheel.
13. Align the hole of the steering wheel and pipe. Secure in place with screw and nut with cap.
14. Install side view mirrors by inserting them into the holes on the side of the car in the top of the doors ensuring they face backwards.
15. Insert hooks on rear of seat into matching holes on the car above the seat compartment. Secure in place with two rotary knobs.
Step 4: Charging and Batteries (Adults Only)
1. Insert to AA batteries into the remote by unscrewing the back cover and matching positive and negative ends of the battery to the positive and negative terminals.
2. Turn off the power to the car before charging.
3. Plug the charger into the charging port in front of the seat just below the front edge of it. Plug other end into standard wall outlet.
4. Initial charge takes 18 hours, all others are 8-12 hours.
5. Recharge regularly (About once a month), even when not in use to preserve the battery.
6. Do not expose battery or electronics to water or fire. See your local disposal agency if battery ever needs replaced.
7. Only use the provided charger and ensure it is in good condition before each use with no exposed wires or build up (dirt or otherwise).
8. If there is any smoke, irregular smell, noise, or other irregularities when charging, unplug and replace before further use.
Step 5: Troubleshooting
Symptoms / Resolutions
Out of Order
1. Unplug charger from wall and car.
2. Check gear position, switch between positions to ensure it is not stuck between positions.
3. Check weight load, remove overload and try again in 60 seconds.
4. If using R/C function, light on remote should stay solid lit. If flashing, seek repair/replacement.
Poor Operation / Low Speed
1. Ensure full charge by charging for at least 8 hours.
2. Check weight load, remove overload and try again in 60 seconds.
3. Double check wheels and review proper installion instructions.
Battery Not Charging Fully
1. Check battery connection, review battery installation instructions.
2. Visibly check for battery or charger damage. Seek repair or replacement if damage is found.
3. Test power outlet for power with another device that is known to work. Call an electrician if it is not working.
Step 6: Emergency Stop Switch
As part of this build, we will be including an immediate shut off switch for emergency use, or to prevent accidental acceleration when loading or unloading, or when not in use. It will be mounted on the rear of the vehicle for easy access during emergency situations.
1. Cut the green wire that is apart of the red, white, blue, and green wire bundle
2. You will need to cut two 20 gauge wires that are approximately 2.5 feet each
3. Use the wire strippers to cut off about 1.5 inches of the insulation on each end of the green wire and the two 20 gauge wires you just cut
4. Twist one end of the green wire to one end of the 20 gauge you just cut
5. Repeat step 4 with the second 20 gauge and other green wire.
6. Twist on a wire nut to each end of the wires you twisted together
7. Drill a 3/16 hole into the back of the car, make sure there is nothing behind the spot where you want to drill your hole at.
8. Mount the switch to the car, you'll have to push the threaded side of the switch through the hole from the inside of the car and thread the nut on from the front side, make sure the nut is tight so the switch fixture doesn't move around.
9. Crimp the female disconnect terminals to each end of the 20 gauge wire you cut, this is the opposite end as the end that you put the wire nut on.
10. Insert the female ends to the male tabs on the switch, it doesn't matter which tab the crimped disconnect attaches to
Step 7: Raised Floor
1. Measure floor dimensions (~6 x 8 inches)
2. Cut kick board foam to length and width.
3. Cut (2) Velcro strips (~5 inches) to Velcro the cut kick board foam to the floor.
4. Remove paper from back of Velcro strips exposing glue, properly align and stick to both the floor and foam pad. Press firmly to ensure adhesion.
Step 8: Rewiring Acceleration Into Button
1. Remove the seven screws from the back of the steering wheel, disconnecting the face of it from the drive shaft assembly.
2. Drill three holes along the edge of the face of the steering wheel at the bottom, and each side.
3. Drill three holes on the edge of the Big Button that line up with the three just drilled (try to keep the wire that comes out the back of the Big Button towards the top).
4. Drill a hole in the drive shaft just behind where the face of the steering wheel would be as seen in the picture.
5. Connect the Big Button to the steering wheel face with three nuts and bolts.
6. Run the wire through the drive shaft and dashboard following the wire that already goes through the dashboard.
7. Remove the gas pedal by pressing the tabs in on it from the bottom of the car.
8. Remove the two screws disconnecting the wires from the pedal.
9. Cut the connector off the end of the Big Button.
10. With wire nuts, connect each of the wires from the Big Button to the wires from the gas pedal.
11. With the seven previously removed screws, reconnect the steering face to the steering shaft. (See Original Assembly to complete installment of steering wheel).