update: The first page or so is the old xtracycle build and page 2 gets in to the Big Dummy build. This is a long term project.
Hi folks, I'm going to be doing a build thread for my e-bike here. It should be pretty fun! I've got most of the major parts here so things should move along (I hope). I'll be posting some pics and info as I go along.
So let's start at the beginning, this is a Kona Hoss that I built from the frame up. It's got pretty decent components: Hayes hydraulic disk brakes, Shimano Deore (LX,XT, and XTR mix) drivetrain, Marzocchi Dirt Jumper III 20mm fork, Loco downhill wheelset, and a set of Maxxis Hookworms.
I'm a big dude, so I picked a Hoss as it's built for Clydesdale sized riders. I have never had a bike that feels like a proper fit until this one. The frame is very stoutly put together, but in aluminum so it's light. It's a 20" frame with a 5" riser bar, the bike has a big crossover SUV feel to it. I've ridden it on a few trails, but mostly it's an Urban Assault Bomber, put together for street and city thrashing, light trails, and night riding.
This is going to be my second e-bike build and I'd like to give a brief mention to my first build, which I regret not documenting. The first was an older rigid Cannondale MTB with a used Wilderness Energy brushed front hub motor running on 36v 10.5ah SLA's, then converted to 10s 10ah Lipo, then 11s 20ah lipo. I had also upgraded the motor leads from 16ga to 12ga and all power connectors to Andersons and added a Cycle Analyst. It was a decent ride with a 27 MPH max speed (no pedaling). It has a relatively new 35A controller and new brushes. After a few hiccups getting going, it turned into a reliable ride that was a lot of fun. The only thing I would have liked was more low-end acceleration, but this was a minor complaint. I knew after a few weeks of riding the e-Cannondale, that I would be upgrading sooner or later, so I didn't try to push it much, just make what I had as reliable as it could be.
Unfortunately, I knew I'd be using the lipo's from the e-Canny and needed the bike for pedal-ready for other reasons (explained later) so, I de-converted it in a hardcore fashion. I went from all the e-bells and whistles to a 69er, 7 speed, single front disk, bullhorn bar minimalist messenger style bike. I like it this way, but certainly miss getting my e-bike fix.
Initially, I had a decent vision of what my build was going to be and set about gathering parts. I was going to do a frame up build of a rear drive cargo bike. In addition, I tried to source as much as possible through Endless-Sphere members because that is where all the cool kids do their shopping.
So, let's get started!