I converted a cargo bike to an e-bike — here’s what I learned

For approximately seven years during my twenties, amidst a period of self-discovery, I temporarily abandoned my nerdy interests and picked up a new hobby: cycling. Little did I know that this hobby would eventually become a way of life. In what I now view as my time in the wilderness, I sold off my extensive collection of video game consoles (something I regret), stopped purchasing computers, got rid of my car, and quit my job in data aggregation to become a pedicab driver. At that time, gig jobs weren’t as popular as they are now, but I enjoyed being a pedicab driver and eventually became a guide at a small bike tour and rental company.

One of my responsibilities at the tour company was bike maintenance, and our mechanic taught me some useful tricks like wheel truing and bike assembly. While I wouldn’t consider myself a bike mechanic, I did become proficient in basic bike repairs.

One day, a retiree who enjoyed flaunting his possessions brought in a Copenhagen Wheel for servicing. This e-bike kit contained a battery and motor integrated into the rear hub of the wheel. When he allowed me to test ride it, the extra boost of acceleration with every pedal stroke completely changed my skeptical mindset.

Years went by, and I eventually acquired my own e-bike. These bikes are incredibly enjoyable and convenient, and for some people, they can even partially or fully replace a car. They are particularly great for short trips as they are easier to park. Even if the battery runs out, you can still ride them as regular bicycles, albeit a bit heavier.

While electric cargo bikes are even better substitutes for cars, the high price tag prevented me from considering one. However, fate intervened, and an unexpected opportunity presented itself that allowed me to convert my partner’s rarely used e-bike into an electric cargo bike.

The conversion process turned out to be more complex than I initially anticipated. Nevertheless, with some surprises along the way, the conversion was successful, and I now have a functional electric cargo bike.

The most challenging aspect of the conversion was mounting the motor, but it was a relatively straightforward process. I had to remove the crank arms, front chainring, and bottom bracket using specialized tools. After cleaning the frame’s bottom bracket shell, I greased up and installed the motor’s bottom bracket shaft. Securing the Bafang motor involved using a bracket, locknut, and outer locknut.

Next, I had to install the speed sensor, which proved to be a bit tricky due to the elongated cargo frame. Thankfully, I found a suitable spot after some trial and error. However, I encountered an issue with the cable that connects the speed sensor to the handlebar display—it wasn’t long enough. I had to order an extension cable, causing a delay in completing that part of the job.

Despite this setback, I proceeded with other tasks, such as replacing the grips and attaching the display, which were relatively easy. However, I faced another obstacle—the existing shifter and brake on the cargo bike were integrated, and I couldn’t reuse the shifter with the new brake lever included in the motor kit. This meant I had to replace the shifter, rear derailleur, and cassette.

Unexpectedly, the large tripod bike repair stand tipped over, causing chaos and frustration. It knocked everything off the table, including the master link for my chain, which flew away and went missing. I had to reluctantly give up searching for it and buy a replacement.

Exhausted and disheartened, I decided to take a break and resume the project the following day.

I couldn’t determine the cause of the issue I was facing. It could have been the loose and drooping kickstand, which may have been hitting against something…

 

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Denial of responsibility! Samachar Central is an automatic aggregator of Global media. In each content, the hyperlink to the primary source is specified. All trademarks belong to their rightful owners, and all materials to their authors. For any complaint, please reach us at – [email protected]. We will take necessary action within 24 hours.