Little workshop insight

'Kona Minute' Brighton Ebikes edition on the beach near the old West Pier in Brighton. Fitted with Bafang BBS01B 36V 250W mid-drive motor and a Samsung 30Q cell 540Wh battery pack. Delightful!

Of the hundreds of conversions I've now performed, I rarely take before or during photos leaving the photoshoot solely for the completed job; a selection of which can be viewed in the  website gallery.
So, whilst a short video of a complete Brighton E-bikes installation is on the cards, below are some photos taken during a recent conversion of a 'Kona Minute'. This little beauty is to be our family school run / shopping / errands transport; a true car replacement for local journeys and is just perfect for the job.  
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First things first, with the pedals already loosened, it's off with the crank arms and out with the bottom bracket.​

As the Bafang BBS01B motors run a single chain ring, the front derailleur will no longer be required, so that goes and the chain is removed for a clean or replacement depending on the level of wear.

In the early stages of the strip-down with the cranks, bottom bracket, chain and front derailleur removed.

Ready for a clean up. Wheels off, handlebar grips, brakes and front shifter are removed leaving only what will remain in place for the build.

There is little point in not taking the opportunity to give the bike a good degrease and clean, especially the transmission, so a thorough clean and lube is performed before proceeding any further. Here, the rear derailleur is transformed to a like new condition.

Before being fitted, the motor is bench tested and the final drive treated to extra Mobilgrease28

The motor is then offered into the frame and set in position, ideally close to the underside of the downtube.

The correct tools for the job. The Bafang securing nut and lock ring will be secured to the correct torque levels using specific sockets and of course a torque wrench.

The retaining plate is positioned with the raised face inwards to contact on the bottom bracket, then the main M33 4-notch securing ring is fitted followed by the lock-ring to the specified torque settings of 50-60Nm and 30Nm respectively.

With the motor now secure, attention is turned to the battery mounting.
First, a hole is drilled in the centre of the metal base plate. This will become the lowest most mount point.

The metal base plate is fitted to the frame with stainless steel M5 bolt, split washer and thread lock. The top section of the battery mount can then be offered up in order to measure where the additional rivnut needs to be fitted.

With the exact position carefully marked with a centre-punch, the hole for the rivnut is drilled in the frame.

The rivnut is fitted and the main section of the battery mounting plate installed.

Motor and battery installed, check!

The main wire harness is run along the downtube on the underside of the battery mount before being connected to the handlebar display and power controls.

The speed sensor is mounted along the underside of the non-drive side rear stay and magnet fitted to the wheel spoke (opposite to valve for balancing).

The gear sensor (from gearsensor.com) is fitted inline on the gear cable.

Lekkie 42 tooth chainring and Buzz Bar crank arms are installed to the correct torque settings.
​The chain is then refitted checking the length is correct.

Although brief and omitting to detail a number of stages such as the cable soldering / heat shrinking, display setting and controller programming, it's a far better log of a conversion than I have kept before.

A quick road test down to the beach and back, followed by any fettling or slight programming changes back at the workshop and it's pretty much ready to go.
So here it is, the 'Kona Minute' Brighton Ebikes edition all ready to provide daily service as a true car replacement for local journeys and much more.
It's already loaded with child, panniers full of groceries and some  flowers for the wonderful lady who keeps us two in check!
Guaranteed to deliver plenty #moresmilepermile for years to come :)