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Cannondale E-bike Conversion

Discussion in 'Quitters' Club' started by hudsonhawk, Feb 21, 2021.

  1. Feb 21, 2021
    hudsonhawk

    hudsonhawk Well-Known Member

    North Texas...
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    So I jumped down the eBike rabbit hole. We will see how much a pain this turns out to be.

    The sacrificial victim is a 2015 Cannondale Trail 5 29er mountain bike. I bought it new and except replacing the seat it is original from the factory.

    20210221_134228.jpg

    The Kit is from Bafang Direct USA (not affiliated with Bafang the manufacturer). It is a 750 Watt middrive motor and can be limited to 20 MPH. This will allow it to stay an electric bicycle under Texas State law and not an electric moped or motorcycle. This means no special license or light requirements to ride it on the road.

    https://www.bafangusadirect.com/bafang-750w-bbs02-mid-drive-motor-and-battery-p/60.htm

    I chose to upgrade to a 52V 17.4Ah battery to increase the range and make more efficient use of the available power.

    The kit arrived today but I don't have time to start breaking down the bike. Tear down includes removing the crank assembly, front shift rail and front shift mechanism from the handlebar.

    20210221_140122.jpg
     
    47v6, dozerjim, Jw60 and 2 others like this.
  2. Feb 21, 2021
    Dave Deyton

    Dave Deyton Member

    Fuquay-Varina, NC
    Joined:
    Oct 12, 2003
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    847
    I like Cannondale bikes. They are very well built.
    Sounds interesting, doing the E bike conversion.
    I think this will be an interesting project.


    Dave
     
  3. Feb 21, 2021
    givemethewillys

    givemethewillys Been here since sparky ran it. 2022 Sponsor

    New Kent, VA
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    I'm looking forward to following along with this build up. Let us know how you like it!
     
  4. Feb 24, 2021
    hudsonhawk

    hudsonhawk Well-Known Member

    North Texas...
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    Okay, who the *bleep* designed the bottom brackets on these? And why would you have a self contained bearing insert that unscrews in the direction of pedal rotation?

    Started the tear down at lunch and ran into that little gem. Luckily I realized it before I applied the 15 lb sledge to 1 ft long wrench on the removal tool.
     
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  5. Feb 24, 2021
    Buildflycrash

    Buildflycrash More or Less in Line. 2024 Sponsor 2022 Sponsor

    Gulf Breeze FL...
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    Jun 5, 2007
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    I like bikes. My wife wants an ebike. Following.
     
  6. Feb 24, 2021
    Mr Vaughan

    Mr Vaughan

    i want a gas powered bike
     
  7. Feb 24, 2021
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    Aug 13, 2015
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    6,656
    Only because you’ve never ridden an e-bike. :twist:
    They’re pretty impressive.
     
  8. Feb 24, 2021
    boopiejones

    boopiejones I can’t drive 55

    California east bay
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    545
    This always seemed wrong to me too, but there’s a good explanation for it: Technical FAQ: Are bottom bracket threads backwards? – VeloNews.com
     
  9. Feb 24, 2021
    hudsonhawk

    hudsonhawk Well-Known Member

    North Texas...
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    The bike has all the parts stripped off that will be replaced or discarded. Both brake levers get replaced with ones that have sensors to cut power to the motor when they are activated. The front derailer/shifter is removed and discarded. Crank assembly removed and discarded. It gets replaced by the mid drive motor.

    20210224_155908.jpg
     
  10. Feb 24, 2021
    hudsonhawk

    hudsonhawk Well-Known Member

    North Texas...
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    Mid drive motor installed and started running the cables on the frame. The motor is clocked up as far as I could make it without interfering with rear shift cable that runs along the bottom.

    20210224_162322.jpg

    It keeps the center of gravity low. This kit does add about 30 lbs to the bike including the battery.

    20210224_162330.jpg
     
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  11. Feb 24, 2021
    hudsonhawk

    hudsonhawk Well-Known Member

    North Texas...
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    Looks like the pedals will be wider spaced than I am used to. Will see how that effects the ride.
     
  12. Feb 25, 2021
    Twin2

    Twin2 not him 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Virginia Beach, VA
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  13. Feb 25, 2021
    baldjosh

    baldjosh Member

    pacific north west
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    Im in...been thinking of doing the same for a while
     
  14. Feb 25, 2021
    Mr Vaughan

    Mr Vaughan

    you dont get the rumbling of a 2 stroke with an electric motor... just sayin.
     
    ITLKSEZ likes this.
  15. Feb 25, 2021
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Liberty Lake, WA
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    Hey, I get it. When I was your age, the first mod to any dirt bike was to remove the silencer.

    I strapped my granddad’s hand-me-down post-war David Bradley chainsaw to my old banana seat, ape-hanger-handlebar bike, and used the actual cutting chain as the drive chain. :ninja:

    One thing I can say about getting older, I’ve come to appreciate stealth. Sleepers rule. Even if it’s on 2 wheels. :D
     
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  16. Feb 25, 2021
    Mr Vaughan

    Mr Vaughan

    :shock:
     
  17. Feb 25, 2021
    hudsonhawk

    hudsonhawk Well-Known Member

    North Texas...
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    Spent my lunch installing the brake handles, controller display, thumb throttle, control pad and speed sensor. Just need to install the cranks, peddles and battery then I can test it. The battery is charging right now.
     
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  18. Feb 25, 2021
    hudsonhawk

    hudsonhawk Well-Known Member

    North Texas...
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    Everything is connected for testing. Need to straighten up the cabling still but time for the test.

    finished.jpg

    And we have ignition!

    display.jpg

    Picked up the rear tire and gave throttle a quick blip. It ran perfect.
     
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  19. Feb 25, 2021
    hudsonhawk

    hudsonhawk Well-Known Member

    North Texas...
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    I am going to need a longer chain. The main drive is a lot bigger than what was on it previously.
     
  20. Feb 26, 2021
    hudsonhawk

    hudsonhawk Well-Known Member

    North Texas...
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    All cabling is cleaned up and went for a quick ride. In the computer I set the tire size to 29 inch and restricted max speed to 20 MPH. I set the 9 speed rear cassette to 3rd to test.

    With boost set to 9 it hit 23.5 MPH on throttle alone. On the lowest setting it reached 12MPH but much lower power draw.

    20210226_122433.jpg

    Even with boost set to 1 (lowest), the bike feels light under pedal power. It is well-balanced and nothing feels awkward or ungainly.

    The power cut off for the brakes works like it should. Even with the throttle held down, application of the brakes turns off the motor.

    Overall really happy with it.
     
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