This could be a really LONG post, because my builds take a lot of time to complete, but it’s not going to be. I’m in no hurry to complete a build, and I think it’s fun solving problems as I go, ordering a different part for an application (which takes time), learning something new, etc. So to make this post as short as possible, I’m just going to review my thought process and mention some places where I had issues that took time to resolve. So here goes:
- You have your bicycle, e-bike kit, tools, and parts obtained from your inventory assessment – good start!
- Strip ‘er down! Remove the parts you’re not going to use in your final build, check your head and crank bearings (replace as needed). Check your cables (replace as needed).
- I start my rebuild with the wheels and brakes (assumes crank, fork and derailleurs are in good shape). On both of my rear-drive builds, I needed to add a shim to the derailleur side axle so the gear cluster provided by Voilamart would clear the chain stay. A washer obtained from the local hardware store did the trick.
- Next, install shifters, brake levers, and throttle (I prefer a thumb throttle over the one provided by Voilamart, though you’ll need to do some soldering for this mod) – helpful video. Install you new cables and cable guides as needed. Brake and derailleur tuning will happen later, so this is just to get things routed and arranged properly. Make sure you have an appropriate amount of play in you cable guides forward of the handlebars so the bars rotate freely.
- Figure out where you want to mount your controller box. My first build allowed me to locate the box below the top tube and above the battery. My second build required me to put the controlled on the luggage rack since there was insufficient space for it above the battery. Sort this out BEFORE you start routing wires (of which there are many).
- Route and secure all wires. This is a bit of an art since you want the wires to be out of sight, out of mind, but compromises must be made. Here’s a close-up of my rat’s nest (hence my reasoning behind the name for this website):
Assuming everything is connected the way it needs to be, it’s time for testing and tuning. You’ll want your battery to be charged and ready to go for the next step…