Brighton E-bikes
  • Home
  • About
  • Store
    • Bafang BBS motor and battery kits >
      • Bafang® BBS01B 36V 250W 14.5Ah
      • Bafang® BBS01B-ETM 36V 250W 14AH
      • Bafang® BBS01B-ETM 36V 250W 17.5Ah
    • Lekkie® Bling Rings >
      • Bling Ring BBS01/02(B) - 42T
      • Bling Ring BBSHD - 42T
      • Bling Ring BBS01/02(B) - 46T
      • Bling Ring BBSHD - 46T
      • Bling Ring BBS01/02(B) - 36T
      • Bling Ring BBSHD - 36T
      • Bling Ring BBS01/02(B) - 52T
      • Lekkie BBS01/02(B) spacer
      • Lekkie BBSHD spacer
    • Complete electric bikes >
      • Complete E-bike conversion incl. motor kit and battery
      • Installation service (customer supplies motor kit, battery etc.)
    • Bafang BBS01/02(B)/HD parts and accessories
  • Contact
  • Gallery
  • Testimonials
  • Blog
  • Useful links and resources
  • Terms and Conditions

Little workshop insight

13/9/2018

0 Comments

 
Picture
'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.  
​
First things first, with the pedals already loosened, it's off with the crank arms and out with the bottom bracket.​
Picture
Picture
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.
Picture
Picture
Picture
In the early stages of the strip-down with the cranks, bottom bracket, chain and front derailleur removed.
Picture
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.
Picture
Picture
Before being fitted, the motor is bench tested and the final drive treated to extra Mobilgrease28
Picture
Picture
The motor is then offered into the frame and set in position, ideally close to the underside of the downtube.
Picture
Picture
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.
Picture
Picture
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.
Picture
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.
Picture
Picture
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.
Picture
Picture
The rivnut is fitted and the main section of the battery mounting plate installed.
Picture
Picture
Motor and battery installed, check!
Picture
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.
Picture
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).
Picture
Picture
The gear sensor (from gearsensor.com) is fitted inline on the gear cable.
Picture
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.
Picture
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 :)
Picture
Picture
Picture
0 Comments



Leave a Reply.

    Picture

    BLOG

    Archives

    September 2018
    February 2018
    February 2017
    January 2017
    December 2016
    October 2016
    September 2016
    August 2016
    July 2016
    June 2016
    May 2016
    April 2016
    March 2016
    February 2016
    December 2015
    November 2015
    October 2015
    September 2015
    August 2015
    July 2015

    Product overview
    Visit us on Facebook
    Visit us on Google+
    Visit us on Instagram
    Visit us on YouTube

Location

Hove
Brighton
East Sussex
United Kingdom
Test rides and demonstrations by prior arrangement.
Contact the workshop direct on
​01273 930700
​07824 776399 or email brightonebikes@gmail.com
Picture

What our customers say...


"I have just completed 2,000 miles on a Bafang powered bike converted by Brighton E-bikes and am convinced that bespoke after-market conversions are the way forward.
I first met Darren whizzing around on one of his conversions on a local bike ride last summer. I was riding my 1990 Specialized Stumpjumper which had given me really outstanding service with frequent 20 mile rides on the hills before breakfast and on full days easily doing double that amount. For a few years though I had been struggling along with damaged knees caused by sports injuries and wear & tear and this had prevented me doing more than 10 miles on relatively flat ground without pain. We immediately started chatting about bikes in general and in particular about the Bafang motor unit he was using for his bike conversions. So I set him a challenge “put one onto my 25 year old Stumjumper in the next week and I’ll take it to France on holiday” When he started work on it he phoned the same evening to say the bottom bracket bearing was so corroded it was looking doubtful he could remove it without the possibility of damage in which case it was likely the bike would no longer be usable - he wanted a decision? It was made immediately “keep at it”. After another 2 days of soaking and fiddling he finally succeeded and exposed the shell of the frame which cleaned up beautifully. The bike was delivered by Darren a day or so later. He looked as proud as punch and I was delighted. The bike had been called many things during this process and there is a picture on his website “A Pig of a Job” demonstrating what can be achieved with patience, skill and due diligence.
Since that holiday I have been completely sold on the product and Darren’s passion and enthusiasm, so in January I purchased a new Specialised bike. The motor unit was transferred onto the new bike and I am now doing the same distances and rides as before without pain or stress to the joints, but having the full benefit of the aerobic exercise. It’s so good to ride the South Downs Way and see the top of the hills again! Thank you Darren & Brighton E-bikes."
Trevor  Shoreham  2016

See more testimonials CLICK HERE

Contact Us

Telephone
Workshop 01273 930700
Mobile 07824 776399

CONTACT VIA EMAIL
Opening hours.
​Mon-Fri  09.00-17.00
Back to home ->
  • Home
  • About
  • Store
    • Bafang BBS motor and battery kits >
      • Bafang® BBS01B 36V 250W 14.5Ah
      • Bafang® BBS01B-ETM 36V 250W 14AH
      • Bafang® BBS01B-ETM 36V 250W 17.5Ah
    • Lekkie® Bling Rings >
      • Bling Ring BBS01/02(B) - 42T
      • Bling Ring BBSHD - 42T
      • Bling Ring BBS01/02(B) - 46T
      • Bling Ring BBSHD - 46T
      • Bling Ring BBS01/02(B) - 36T
      • Bling Ring BBSHD - 36T
      • Bling Ring BBS01/02(B) - 52T
      • Lekkie BBS01/02(B) spacer
      • Lekkie BBSHD spacer
    • Complete electric bikes >
      • Complete E-bike conversion incl. motor kit and battery
      • Installation service (customer supplies motor kit, battery etc.)
    • Bafang BBS01/02(B)/HD parts and accessories
  • Contact
  • Gallery
  • Testimonials
  • Blog
  • Useful links and resources
  • Terms and Conditions