GoBabyGo Installing an AbleNet Big Red Switch & Emergency Stop (Part 1)

The most common and impactful modifications we perform involve transitioning the vehicle from standard foot-pedal operation to a fully accessible hand-control system. This process centers on installing a highly sensitive AbleNet switch for actuation, supported by a relay to manage electrical loads, and an emergency stop (kill switch) for essential parent-controlled safety. This modification provides a safe, responsive, and fun driving experience for every child.

This Instructable details how to safely modify the electrical wiring: tracing the power, adding a relay (if needed), installing an emergency stop switch, and installing an AbleNet Big Red switch.

Overview:

1. Part 1: Installing an AbleNet Big Red Switch & Emergency Stop (this one).
2. Part 2: Adding on a Steering Bar.
3. Part 3: Adding on a Grab Bar to the Steering Bar.

Materials:

1. AbleNet Big Red Switch
2. Sanyou SARL -112DF (Single pole double throw) relay (if needed, see Step 3).

Hardware:

1. 16-gauge wire
2. 14 AWG wire
3. 3 zip ties
4. 4 female wire connectors
5. 1 wire nut (for temporary use)
6. Crimp connectors or heat shrink

Tools:

1. Wire Strippers
2. Wire Cutters
3. Voltmeter
4. Phillips Screwdriver
5. Mallet
6. Dremel or jigsaw
7. Power Drill

Significant observations from past cars:

There are plastic wrenches made to put nuts on the axle.

When attaching the steering column be sure to run a bolt through the white terminal that controls steering for the remote control, but it should be left out in order to modify the electrical system later. The same applies to the small metallic pin located right above the "hook" part of the steering shaft.

Do not install the hubcaps until the axles are in place (They snap on, but are difficult to take off.)

Be sure to attach the loose red wire to the battery or the car will not run.

When attaching the motors to the wheels, check to make sure forward and reverse go in the correct directions.

SAFETY: MAKE SURE THE CAR IS OFF BEFORE MAKING ANY ELECTRICAL MODIFICATIONS!

Remove the plastic cover beneath the vehicle that will give you access to the cables.

There are two wires coming off the on button for the car:

1. charging circuit (brown)
2. pedal control (red)

Use a voltmeter to check which cable is supplied with a continuous 12V:

1. With the car off, test both wires with the positive end of the voltmeter, while the negative end is on ground (check that the brown cable goes to the charging circuit and the red to the pedal control).
2. With the car on, check these wires again following the same procedure; they should both read 12V.

If these both read 12V, then string the cable connected to the button and the cables that were attached to the pedal (excluding the brown one) to the back compartment beneath the seat.

You will need to connect another cable to get the length needed to reach the back.

Cut the cables from the pedal.

Cars that come with a remote will typically already have a single pole double throw relay pre-installed. To check, lift the back wheels of the car, turn on power, and while pressing the accelerator pedal listen for an audible click near the control box. If a click is heard, a relay is installed.

If your car comes without a remote, and no audible click is heard, you may need to install a Sanyou SARL -112DF (Single pole double throw) relay.

Measure the diameter of the switch threading, and select a drill bit close to the size needed (it is better to start off with a slightly smaller bit than the diameter, because you don't want the switch to fall out of the hole in the end).

Optional: Make a pilot hole if necessary, the plastic may not work well with the bigger drill bit.

Take the nut and "on-off" tab off the emergency stop switch, and make note of the slot on the "off" side of the switch.

Place the threaded end of the switch through the hole from underneath the car--with ON facing up and OFF facing down, screw the nut back on finger tight, and tighten with pliers if necessary.

You'll connect the wires in a future step.

Cut 1 foot of 14 AWG wire, splice it into the wire nut that contains the wire coming back from the emergency stop switch.

With the other end of this wire, attach a female wire connector and attach to pin 86 on the relay.

To finish the relay, drill a small pilot hole with a small drill bit, then use a 1/4 in. screw to mount the relay to the wall of the inner hood compartment, such as the backside of the front grill.

Flip the car over, remove the plastic pieces covering the backside of the pedal.

Test both pedal wires with respect to ground, find the the wire with a positive voltage difference, cut this wire and attach this wire to pin 87 on the relay after crimping a female connector onto the end of the wire.

For the other wire:

1. Cut the other wire
2. Crimp a female wire connector* onto the end of the wire
3. Attach it to pin 30 on the relay after

*It is useful to use a two stage female wire connector on these wires due to their size. A two stage female wire connector works by having a large pair of pliers crimp the outside, then using the tip of a pair of wire strippers to crimp the center.

Look for one of these three common methods for attaching the steering wheel to determine how to remove it:

1. Clip Method: The steering wheel is secured with clips on two sides of the shaft. Carefully pry the clips loose to remove the wheel.
2. Screw Method: The wheel is attached with a screw, typically a Phillips head. Unscrew it to detach the wheel.
3. Pin Method: The wheel is held by a pin. Use a rubber mallet and a screwdriver to gently push the pin out.

Disassemble the steering wheel:

1. Once the steering wheel is removed, place it on a flat surface.
2. There will be between 6 to 10 screws holding the pieces together. Unscrew these to take the steering wheel apart.

Modify the steering wheel:

1. Set aside the back side of the wheel
2. Use a Dremel on the front half of the wheel to cut out the central portion of the wheel (they typically are not flat, and you need a flat surface to attach the Big Red switch).
3. Trim edges of the steering wheel so the Big Red switch is set into the steering wheel.
4. Test the fit the button: if the fit is satisfactory, drill out one of the screw holes on the bottom part of the back half of the wheel to fit a zip tie through to prepare for Step #3.

Reassemble the wheel with as many screws as possible (not all of the screws will be used again).

Feed the button wires through the trapezoid-shaped hole at the back of the wheel, NOT in the circular hole.

Zip tie the steering wheel at 10, 2, and 6 o'clock positions on the wheel. The 6 o'clock zip tie will go through the screw hole you widened out earlier.

Cut off the excess on the zip ties, make sure the cut ends are on the back side of the wheel, and file down the nubs as much as possible to prevent scratching of hands.

Find a wire that leads to ground and cut it.

Wire one end of the Big Red switch to the ground wires, connecting them with a wire nut.

With the second wire from the Big Red switch, crimp a female connector onto it and attach it to pin 85 on the relay.

Reassemble the dash and windshield.

Reattach the steering column using the same method you used to remove it.

Run all wires through existing channels and reattach the plastic cover beneath the vehicle.

Note for remote controls: If you wish to have remote control of the car, bolt the steering column to the white motor from underneath the car.

Follow the additional Instructables linked in the Introduction if you would like to add a steering bar or grab bar.