Tats BigHit 3 BBS02 / Demo 8 ii phaserunner h35 Build

[Tats]

Bought a specialised Big Hit 3 second hand - this bike is dual suspension with a 73mm BB. Front forks are Marzocchi 888vf with a Fox DHX 3.0 rear.
Converting with a BBS02 later model 36v 500w with the latest controller - evcomponents were the cheapest at the time with their sale.
Saw a tip about using the car bike rack as a work-stand - works a treat and save the back.

2006 model specialised big hit 3

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73mm Howitzer BB

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Pedal removed easily - bike showing signs of servicing

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Frame has a chain guide on it - bolts seized so WD40 applied

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Bottom bolt snapped - no need to easy-out but would do if converting back to normal bike

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BBS02 clearance ok on the chain stay

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BBS02 sits between chain guide mounting so a little low, but it is secure

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BBS02 mounting from the non-drive side

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Re-purposed the spacers from the chain guide to bridge the BBS02 gap for the small mounting bolts/bracket

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Bolts supplied too short for the 73mm BB - lucky I have some longer ones

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Spacers, small bolts and main nut in place

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Managed to fit second glamour nut - I like to have these double locked

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Bit more grease please Mr Bafang - easy to check when fitting

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Chain line is awful - need to get a spider / bling ring

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Wiring begins - nice gaps around BBS02 to keep things neat

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Wiring the next stage - and making a mount for CA and display using this.

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[KalSteve]

Looks like it will be a nice build. I have one of those bikes and have been tossing up putting a BBSHD or a Cyclone on it. Thanks for the log with good pics.

[Tats]

Hi Steve, I suspect the hd will foul the mounts for the chain guard. Could cut the lower one off for more clearance though. The seventh picture shows the mount from the front. It's only about 12-15 mm wide.

[Tats]

Battery mounting will be in a bag on a rack - the topeak beam rack with bracing on my reign is all good, but I'm splashing out and going for a different option on this bike.

So here is an outrageously expensive rack... Thule Pack 'n Pedal Tour Rack.

Box

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Contents of said box - platform, braces, bolts and frame

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Fits without fouling any cables or brake lines

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Side view

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Nice and level

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Claims 25kg load limit - certainly a lot more stable than the braced topeak rack off the seat post

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Once I figure out how to secure the bag, rear wiring will continue

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I'll check how the tightness etc of the rack goes - but it's dead easy to fit and a real work of art and design - I'm impressed so far.

[Samd]

Those frames make a nice cut and shut if you're game. Battery drops in the downtube.


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[Tats]

Yeah nah, not game enough mate lol. Saw a pic of how thick the frame material was, really surprised me - these things are strong as.

[Samd]

Haha when you've seen a big drop offroad it makes some of our stresses seem small huh.
Should be a nice rig when done.


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[Quokka]

looks nice tats, i really dig those frames. I detect a trend here... Slowly you are building up your power from your old giant
Also, i have all the whacky bafang tools to tighten the bbs down. If you need them ping me

[Tats]

Thanks Quokka, I have a C-spanner and BB ring already. Cheers.

[Tats]

Old display for now - will ad the colour one later

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Quite happy with the bars like this - will add better grips / bar ends though

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Still got to figure out how to best secure the bag to the rack - and I've ran out of black cable ties.....

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[Tats]

Used topeak beam rack slider and rail - bolted this to rack top using off-cuts of plumber hanging brackets and a couple of cable ties. Will paint this black when I get round to it.

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Final position of the topeak bag housing battery and clothes/tools assorted junk for the commute.

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Moved rear shock position from slack to steep and this has gave me a little more room behind the seat. Rear shock air pressure increased to 175lbs and pedals nicely with very little bob. With the knobbies and a bent rear disc its still quicker than the Giant Reign on the schwalbe big apples and is better over the hollows. On the Reign I get a bit of a wallow but this just soaks it up. Swapped over the spider/chainring and this has improved the chainline a lot.

Still to do - fit colour display, fit a rear mudguard to protect shock, change/straighten rear rotor, get slicker tyres and fit the mr tuffy liners, change the white cable ties, figure out how to de-clutter the cockpit now I've added the lights and garmin.

Pretty easy bike to do the conversion to - I recommend them.

[Tats]

Colour display fitted - pretty happy with this setup

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New boots and black cable ties

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[Tats]

Electric bike reviews hackers guide to BBS programming does not have the EM3EV settings correct - the pas settings are very different. I plugged in my BBS01 with Paul's 25A controller, read the flash from this controller and wrote it to the flash on my BBS02 ver B controller. Much much better settings that stock and the hackers guide.

[Tats]

Six weeks and about 750km later and the Thule rack is great. Tightened the straps a couple of times and lost a nut/bolt on the second ride but now it's really really solid. Found the topeak fixer 8e mount online and now have the handlebar bag mounted too. For commuting this set up is all I need. If I need any more carrying capacity any number of panniers would do - but then it'd be a touring bike. Albeit with very nice suspension lol.

[Tats]

1,200 km and had an issue last night - chain hopped off, broke one side of a link and bent the shimano chain ring. Chain was still in one continuous piece but the inner link had broken. Managed to use pliers to straighten chainring, chose gear with straight chain line and limped home. Will be fitting spare new truativ chainring and a sram pc-971 chain this weekend. Guess I need to make the change to Lekkie and reduce my 9 gears down a bit.....

Note to people when you do have a chain issue on a mid drive - SWITCH EVERYTHING OFF - if you accidently hit throttle or trigger PAS and your fingers are in the wrong place, you could hurt yourself and possible even lose some. Happened to a mate on his motorbike when it dropped into in gear on the centre stand.

[2old]

You might want to look for the chain from SRAM's EX kit (specifically made for ebikes). From my perspective, three gears are plenty with the BBS02 (11-17-28 with 8-speed spacing); allows the alignment to be straight in the "17" and one click off in the other two gears.

[Tats]

Wind against I need the 12 as well as the 11 to keep the cadence in the right spot so on my ride I probably need max of 5 gears - have looked at the ebike sram stuff in past but it was exxy and local shop didn't have it. Future possibility if I break this chain - it was on the bike when I bought it 2nd hand and was fine on a chain stretcher but already had a link in it. Maybe it was damaged.

[the12be]

you need to remove the broken link and add one of these

https://www.google.co.uk/?gfe_rd=cr&ei= ... chain+link

[Tats]

It was a full link in the chain that broke unfortunately. I carry KMC missing links with me, but had forgotten my chain breaker (doh). Couldn't get the half broken link out with the tools I had so had to limp home. Breaker now in my bag.

[Tats]

Upgraded ca to v2.4 software-very easy to do and display a bit clearer. Justin does some real quality work, if only windows upgrades were as easy...

[Tats]

Big graunchy creak from left pedal developed, but wasn't the pedal - took off crank arm and inspected thrust bearings and found no nylon or aluminium washer as fault finding and you tube suggested. Repacked everything with grease added nylon washer and all seems good now.

In other news - installed an em3ev 14s9p 30q, mac 8t kit on a friends bike today - 9fet 30a controller. That thing is rapid! On full throttle and pedalling I could just keep up with the mac using 14a on its lowest setting....it's got the 3way switch but going to put a pot on it to turn it down a bit. Very nice kit tho and installed real easy.

[Tats]

1,750km all good. Rear rack is brilliant. Upgraded satiator firmware to 1.15 - works a treat.

[Tats]

New project begins...first DD for me

[Quokka]

About time you built a real bike

[Tats]

Lol - gonna be an hs3540 with a phaserunner and cav3.....running at 36v