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Zerotow Boogie V3 Hull Replacement

Introduction

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

What you need

    • 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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  2. Zerotow Boogie V3 Hull Replacement, Remove GPS: step 2, image 1 of 1

    • 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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  3. Zerotow Boogie V3 Hull Replacement, Loosen the Case Screws: step 3, image 1 of 1

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

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  4. Zerotow Boogie V3 Hull Replacement, Remove the top plate: step 4, image 1 of 3 Zerotow Boogie V3 Hull Replacement, Remove the top plate: step 4, image 2 of 3 Zerotow Boogie V3 Hull Replacement, Remove the top plate: step 4, image 3 of 3

    • 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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  5. Zerotow Boogie V3 Hull Replacement, Remove the Main Steering Gear: step 5, image 1 of 3 Zerotow Boogie V3 Hull Replacement, Remove the Main Steering Gear: step 5, image 2 of 3 Zerotow Boogie V3 Hull Replacement, Remove the Main Steering Gear: step 5, image 3 of 3

    • 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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  7. Zerotow Boogie V3 Hull Replacement, Remove the Idle Gear: step 6, image 1 of 1

    • Remove the Idle gear

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

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  8. Zerotow Boogie V3 Hull Replacement, Remove the Cable Guide: step 7, image 1 of 1

    • Remove both orange cable guides

    • Remove the tube from the cable guide

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  9. Zerotow Boogie V3 Hull Replacement: step 8, image 1 of 2 Zerotow Boogie V3 Hull Replacement: step 8, image 2 of 2

    • 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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  10. Zerotow Boogie V3 Hull Replacement: step 9, image 1 of 2 Zerotow Boogie V3 Hull Replacement: step 9, image 2 of 2

    • 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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  11. Zerotow Boogie V3 Hull Replacement, Remove Steering Motor: step 10, image 1 of 2 Zerotow Boogie V3 Hull Replacement, Remove Steering Motor: step 10, image 2 of 2

    • Unscrew the M4x10 screw using a 3mm allen key

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

    • The steering motor assembly can be difficult to lift out. It is only held down by the single M4 screw. Wiggle and rock forward and back to lift out.

    • 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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  12. Zerotow Boogie V3 Hull Replacement, Remove the Castle Nut: step 11, image 1 of 1

    • 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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  13. Zerotow Boogie V3 Hull Replacement, New Spacer Ring: step 12, image 1 of 2 Zerotow Boogie V3 Hull Replacement, New Spacer Ring: step 12, image 2 of 2

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

    • Remove and discard this spacer ring.

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  14. Zerotow Boogie V3 Hull Replacement, Installation of new Hull: step 13, image 1 of 2 Zerotow Boogie V3 Hull Replacement, Installation of new Hull: step 13, image 2 of 2

    • 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 needs to be flush with the case

    • When installing the motor, support it from underneath using the trolly cross bar. There should be no gap below the motor and the hull.

    • Ensure that the small cables are all in their slots of the orange PCB tray before installing the top plate. if you do not do this they will pinch and fail over time.

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

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Finish Line

Author

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Mark Duyvesteyn

Member since: 02/11/26

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