A Saturday Project of fun!
Decided today to rework the original forks to try and get the front wheel and motor on this trike. There were two main issues here I had to consider as pointed out by neighbor David who used to own his own bike shop...lucky me, huh. The first was that the axel was too fat for the slot on the forks and the second was the forks were too narrow. In starting this I had the forks and front wheel off the Columbia "American Built" trike already.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/Before_The_Wheel.jpg
The Hilltopper 250watt kit is more for modern bikes with at least 100mm clearance between the forks and about 11mm width for modern axels.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/Too_Small.jpg
As you can see, the forks were just too narrow from the Columbia. So the first issue was to widen the forks. In this case I decided to goto our garage bench where an old vise is mounted. I would place the forks over the vice outside edges and widen the vice which would expand the forks slowly, hopefully with no cracks to the fork Johnies. This was the strategy below as you can see.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/Widen_Forks.jpg
Upon widening the forks, I got them to where they would clear the wheel. It was close but workable so far. Issue two was that the axel was to fat to fit the mount in the forks. So Dremel cutting wheel to the rescue. BTW, I also used a grinding attachment for the Dremel. One of the most handy tools I have.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/Dremel_Tool.jpg
Here is the fork. You'll notice it was very minute I only had to remove a very small piece along the black marker line about a 1/16 wide.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/Widen_Notch.jpg
I sat and worked the fork ends for about 30 minutes to get them ground even and as close to a fit as I could get. It wasn't perfect but close enough to work.
I was able to mount the front wheel and later adjust it after a short time. Here is what it looks like on the original Columbia Forks.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/Mounted_Wheel.jpg
Next I mounted the battery which comes in a carry bag with Velcro straps to the rear basket and it was a quick job, no hassles here. I routed the plug through the front of the basket to wire it up.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/Battery.jpg
Note: The battery has an on/off switch which is a nice deal.
I was disappointed yet amazed how simple the throttle was. They say simplicity is all the rage. In this case I removed the Velcro strap which came with it as it was bulky and ugly and used ties instead. Neat and fast since I have bags of these. The throttle would have been nice with a twist throttle, but instead you get the cheapest red button you can press. It felt like it will break in a short time. Maybe the manufacturer can offer a twist throttle option as an upgrade. By the way they include about 6 or 8 ties of their own for all the wiring, but have an extra bag on hand as there is a requirement for several more to tie down the wiring.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/Throttle.jpg
The throttle is a simple red push button. More on riding thoughts in a bit.
It seems this went off without a hitch but there were casualties here to consider on this upgrade. First, you can never use the original wheel again once the forks are modified. It is a perm mod and that is what you must decide if you are going to do it.
Second, the Columbia has a rear brake drum in the rear hub and a front brake. The front brake will not be long enough for the new Hilltopper rim, so it has to be removed...No front brake! Rear only. Is it enough? Read on!
Front Brake and fender removed.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/No_Calipers.jpg
Removed the front brake handle too.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/No_Front_Brake.jpg
Third there is clearance on the left side of the front rim as you can see here in this shot at night.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/Clearance.jpg
The main problem is the right side clearance. A believe a few extra washers for axle spacing will alleviate my riding impressions coming in a moment, yes I did ride it today. Spacing issues on the right side fork in the photo below. On right turns the wheel and forks rub slightly at speed. Washers are the solution
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/No_Clearance.jpg
Was it work it? I believe with motorized trikes in the neighborhood of $1,200 dollars and up, it was indeed. Here is the finished trike below.
http://i939.photobucket.com/albums/ad233/slickdude/E-Trike/Columbia_E-Bike.jpg
All Made in America too
My riding impressions. It was dusk and a bit cold out when I got this going. I inflated the front tire to 40 PSI and took it out. Turned on the switch. They had forgotten to ship me my charger so they sent that out and I get it a week from now. So I was hoping they had the batteries all charged up and it turns out they did.
I have to tell all of you I was skeptical on speed because this trike weighs a lot and I have a few pounds too
So I turned the battery on, hopped on it and hit the red button. It moved me across the front lawn with some struggle. Got to the fence, drove past that onto the driveway and then in the street. Then I hit the red button and the ****ed thing took off. I estimate it was around 15 maybe 18 mph. This was mind you on a known slight incline. I was quite impressed by this. Of course on the turns you must slow way down as the trike will tip on you. It was never intended to corner at speed. I found that while turning left it seemed fine. But turning right at higher speeds and the hub rubs the fork. Again, a spacer issue I think can be resolved otherwise off comes the wheel and the fork and vise again.
I must say that for those with an old trike, considering the price of newer motorized ones of any value, this worked and worked well. I don't know the distance but presume as the manufacture suggests it is somewhere around ten miles per charge. That of course varies with factors and is for a new battery. My older Ezip Trailz takes 6 to 8 hours to charge. The charger on this does a fast charge in two to three hours, not bad at all. You can also get an extended battery too and extend the range or the motorized hub will easily handle a Lithium pack with no issues I have been informed. I will update this for fellow members as it continues. Luckily this has given fun and new life to an old trike seldom used by the family. Anyways I hope this proved valuable to others who may consider the project for themselves.