Here is my version of an e-bike build.
I started with my wife's Electra Townie 24. The bike was in fair shape mechanically, but the paint job was scratched and in need of complete re-painting. I removed all the components and was left with this:
I took the frame and fork to a recommended local powercoater (http://www.millerpowdercoating.com/
). They stripped the old paint off and did a great job of painting the frame:
I then rebuilt the bike, using a few of the original components, and upgrading a few--a new rear wheel to handle the increased weight of the battery, new BB7 disk brake for the front wheel, new Sugino XD300 cranks and chainrings, and new Shimano bottom bracket.
The electric kit is an eZee kit from ebikes.ca. (http://www.ebikes.ca/store/store_ezee.php
) I ordered an upgraded battery ( replacing the stock 37v with a 48v 12Ah NiMH) and the CycleAnalyst. The folks at ebikes.ca were very helpful in answering my questions and helping me to select the right kit and components. The eZee kit install was very straightforward, with no problems encountered. All of the connectors between the various parts are different, so you can't mis-connect anything.
I added a Otivia cargo trunk (http://www.otivia.com/cargocache.html
) to hold the battery and provide additional storage. Some lights from the bling department of the auto parts store were mounted on the trunk for safety, along with a MR16 3 1-watt Luxeon headlight. I mounted a main power switch (a 20 amp light switch) and switch for the lights inside the lockable trunk. Here is the finished bike:
I have since added a Pletscher Two-leg Kickstand, Avid Single Digit 7 Rear Linear Pull brake, and a 2nd MR16 LED headlight. I am using a small 2.3 Ah SLA battery to power the 12v horn, until I find a good 48v horn to power off the main battery. I am still working on a better solution to strapping the battery down inside the box--I noticed this morning that the wide Velcro strap has be cut by the aluminum plate under the battery; I think I will try a ratcheting tie-down strap. I also need to improve the catch for the Otivia trunk--the stock one is cheap and bends too easily.
It has plenty of power to pull my petite flower of a body (250 lbs and losing--thanks Weight Watchers!). It is easy to throttle the power back and coast or just use your own power. I had to assist a little on some of our steeper hills, but that is to be expected. The hub freewheels nicely, so pedaling around under your own power works just fine, if a bit slow. My wife has taken it to work a few times, and on a few other rides, and really likes the assist. I think it will really help her get back into a cycling lifestyle.