My Giant Iguana and Trek Marlin 6 eBike Conversion v2.1

footose

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Joined
May 16, 2015
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Hi There!

I'm new to the forum, but I've been playing around with eBike conversion for about a year or so. I started by modifying a mountain bike that I had (Giant Iguana, 2007), but I found that it wasn't suited to be an eBike. I purchased a Trek Marlin 6 (this years!), but I'd like to show how I evolved into what I have right now.

So I live about 13km's from work - traffic is ridiculous and it takes about 30 - 40 minutes to get there. I thought that I could mitigate some of the traffic by using an eBike, so I started looking for conversion "kits". I purchased one from GoldenMotor.ca and began my journey.

I wanted the install to be clean, but I was anxious to get going. I purchased what I deemed the "required parts":

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I started assembling!

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I finished it fairly quickly and was ready to give it a shot. It worked for a little while, but I quickly found issues.

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The biggest problem that I had was that the battery was so heavy for the rack, that it kept breaking racks. On the Giant Iguana, it had absolutely no mounting points for a rack, so I was pretty stuck with broken seat post racks. This also caused the seat to "turn". The bike was extremely rear heavy. I used it for about 8 weeks before winter hit and I gave up on the actual rack problem.

I decided that I needed to upgrade the bike to something that had a rack point mount, as well as something newer. I went into my local store and picked up a Trek that they had on the floor. It had Disc Brakes, and a nicely mounted rack which I thought would be perfect.

So I began to build the Trek. This is the base bike I started with - http://www.trekbikes.com/us/en/bikes/mountain/sport/marlin/marlin_6/# - I didn't pick it for any particular reason, other than it had an actual rack.

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Summer has begun and I have been seriously putting KM's on this bike. I ride it to and from work every day for the last 4 weeks. Thats about 25km's a day, so 500km's (estimated) - I've learned to love eBiking - but I've found a lot of issues with the setup, and I'm hoping to improve it.

I started building v2.1 tonight, and I'm almost complete.

My primary problem was that the bike is really "rear heavy". The Rack has snapped bolts at least 4 times (in only 4 weeks of us), and I've popped 2 tires. The rear heavy really causes the bike to "bounce" alot when even on the sidewalk, or hitting a normal bump. I think this puts a lot of strain on the rear. I've been researching the best way to move this battery to the triangle frame for the last few weeks.

On Thursday I ordered a triangle bag from Amazon and I thought I'd take a shot at converting the battery over to make the bike more reliable.

I got to work this morning, and I'm almost complete - but its 1130pm now, so I have to continue tomorrow. I'll post some pix now, but add details later! Check it out.

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Pretty much just have to tie everything up, get rid of the old rack and give it a test run!

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I'm excited to see the weight difference and how it performs. I'll update the thread tomorrow! Have a great night.
 
Well, think I've finished it off for today!

Wow! i'm not sure how people live with the rear mounted battery. This triangle mount makes a world of difference. The bike is way easier to control, not sloppy nor bounce around anymore. I can't believe the difference. I guess we shall see how it performs this week at work.

Note: I know the rear wheel is smaller - this is because I haven't decided if I'm going to buy a new complete wheel with motor and keep this as a spare or just buy just a wheel and port the motor over. This wheel is off my Giant.

Goes about 42km/h on flat, about 30 up hill and I've had it to 52 downhill (just this morning)

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Charge port I put in the main zipper:

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