BBSHD based eMTB / DH conversion.

HackD

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Jul 3, 2011
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I'd already built a couple motorized bicycles over the years - nothing special - either adapted and recycled engines, or the usual China kit builds. About 6 years ago, i started building another, higher end motorized bicycle build, that kept stalling due to design/component issues..

In the Interim, i had a Problem. Declining Hip muscular condition, being a double hip replacement from 10 years ago. Stationary bicycles and the like in a 'physio' routine is simply uninspiring, demotivating to my 'Squirrel' mind.. I had to get back to two wheels involving exercise, to preserve balance and rebuild strength. I couldn't do it on simple pedal power alone - which would be a barrier to getting a motorized bicycle going, obviously..

By this point, the motorized bike build was long dormant, so time to drag yet another bicycle into the garage.. right? Makes sense.

I was looking for a full suspension bike, and found one on kijiji.ca in short order.. a Canadian marketed 'Gamma Vision' circa 2008.

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In the end, basically all but the Frame and rear shock were replaced. Some components moved on to the Motorized Bicycle on hold, but much of it enriched a local bike cooperative.

Initially it was set up in this manner.. a simple initial eMTB conversion.

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I spent the rest of the Spring and Summer chasing down mechanical weak points, identifying improvements vs need in environment i was using it in, and ended up with this final iteration. I got about 750 km in on 'Exercise' in the local ravines and trails over this summer, so well worth it so far.

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The added side-advantage of this project - it gave me renewed motivation and confidence to re-tackle the motorized bicycle project, as the riding season turns cooler - and with motivation has come creative inspiration. I've also noted improvement in own physical condition.

- BBSHD 1000w mid-drive motor
- 750c Display/Controller module
- 48v13.5ah battery pack with top tube mount mod - good for ~25 km range in current ride environment with 90% charge.
- TEKTRO HD-E725 E-Bike Hydraulic Disc Brake 4-Piston Calipers.
- 203mm Front, 180mm rear full floating brake rotors.
- 11-40t Sunfire rear sprocket upgrade
- Lekkie Bling Ring 42T Chainring (ordered to correct chain alignment issue)
- Thule Pack-n-Pedal Tour Rack and Pannier system
- Maxxis Holy Roller 26x2.25" front, 26x2.40" rear tires.
- Rockshox Boxxer Double-crown DH forks
- 26" Alex Rims
- Extended Bar Perch for Headlight, 750c Instrument cluster
- Bontrager gel touring saddle

This is my regular power-assisted bicycle for my physio use on trails.. the gas powered rendition is expected to be the neighborhood street counter-part, when done.
 
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