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*** Welcome to my PMB blog, the umpteenth! ***
The ebike build
and the quest to ride the Berg 100 in a good time!
25 December 2019
The first ebike Bruce bought was an Ezy Torque. It was ideally suited to commuting around Pietermaritzburg and offered both Pedal Assist (PAS) and a throttle. The front wheel hub motor was a work of art and would go forever. It did present one problem and that was a deterioration of the contact made between the battery and the battery mount behind the seat post. I don't think I would be guessing if I said that this was a fairly common problem with ebikes. He rode it for about x years wearing out two battery packs.
The next bike Bruce acquired was a Scott XYZ and he imported it from PQR. Also basically a commuter and once again another excellent buy, but at twice the price of an Ezy Torque. Unfortunately it also presented battery connectivity problems and being an import made the aquisition of replacement parts for the motor and drive train problematic. He is still riding it.
I started riding an MTB in 2012 once I had retired and initiall workd my way through two of Bruce's hand-me-down MTB's. I finally aquiredmy own MTB, a Merida BIG 9 XYZ in the form of a generous gift from the family for my 70th birthday. It It was especially built for me by Wally Flint from Joweet's Cycles and it has been a real pleasure to ride. So I guess it is understandable that my wife was not too impressed when I suggested that it may be the time for me to put an electric motor onto my MTB.
What to do? Well I very much felt that having an electric MTB would allow me to go on longer training rides along a greater variety of routes starting and ending at our home near the top of Town Bush Road. Riding in the western suburbs of Pietermaritzburg inevitably means you will climb a number of hills during your ride and I felt that I would either be doing it on an ebike or perhaps not doing it at all. Finally I was keen to do the Berg 100 again and arrive at the finish before they start to pack up.
So I started to look at the options. My first was to try and get the Chilled Squirrel to build a bike for me according to my specs. Their response was luke warm. Next I considered buying an ebike, but quicly releaized that I was going to have to spend more money than I had if I still wanted to do the Berg 100 thing. So I decided to look into building the bike myself by converting an MTB into an ebike and when I spotted a Merida Big 9 300 (2017) going for R7k at the Bike Addict, I bought it. Now I need to source a Mid Drive Motor Conversion Kit (MDMCK) and a battery.
A browse on the Internet revealed several sites that could supply a BAFANG BBS02B 48V 750W Ebike Motor Mid Drive Electric Bike Conversion Kit or similar. Unfortunately getting a MDMCK through one of these suppliers seemed somewhat tricky (see the pic below) and so I hesitated to go that route. I then found a local company (Relectro) that builds lithium cell based batteries and also does ebike conversions, mostly using Bafang Hub Motors. The company did have two MDMCK motors available, a 300 watt Bafang and a 500 Watt Bafang look-alike manufactured by the Green Pedel Company. The latter a 48V 500W Middle motor kit with a display (LB01).
Now if I am not mistaken, I have already been critical of Bruce's decision to import a Scott because of support problems. So I guess I should have steered clear of a Green Pedel motor, but the willingness of the Relectro's owner to assist me in my quest, saw Edith and I collect the Green Pedel Company MDMCK when we made the trip to Johannesburg to participate in the 947 Discovery Ride Joburg. We also collected a battery built by Relectro. By the time we left for Joburg Bruce and I had already removed the Bottom Bracket (BB) from the Merida, and I was reasonably confident that MDMCK's BB was the same size and would therefore fit. Here I have to say that I was flabbergasted by the range of BB's in existence, and the extent to which a variety of special tools were required to fit or remove them. Fortunately Bruce had the tool we required to remove the BB fitted to the Merida, and the tool required to fit the Green Pedel MDMCK's BB. Here I should add that the latter tool looks about as old as me and also very similar to the bicycle tool I recall useing as a child.
A couple of days after Edith and I had returned from Johannesburg, Bruce and I started to fit the motor to the Merida. While it has not been a breeze, it has proceeded relatively smoothly. After Bruce had tested the bike using the default electronic setup (24 inch wheel, mph, etc.) we completed the installation by tying off all the cables (too many for my liking) and hacking the electronic setup. After that I was off to our local bike shop to acquire a more comfortable saddle and varios other bits and pieces. The only thing that is missing is a rear view mirror, and as I feel these should be compulsory, the search will continue.
So what is next? I guess I had better ride both my bikes if I am to avoid a couple of pointed comments in due course. I also need to find out how to ride the bike such that I optimize the distance I can get on a single battery charge. Hopefully it will be a figure that allows me to attempt the Berg 100 without having to carry a second battery. If not, the first option is to look at the new (more Ampere Hours) lithium cells Relectro will be using in the new year. If that does not work out, then carrying a second battery is the remaining option. I already have a carrier handy that I will probably fit sooner than later in order to carry my water bottles.
PS The first time I rode the bike another cyclist shouted at me, "Have you fitted a stronger chain?". Yes I have.
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To view a larger image, click on a thumb-nail. Click anywhere within the browser context in order to remove it.
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Well, what is it like?
My first training ride on the E-bike was my stock, "Down and up the extended hill. Going down the hill was no problem and I did that sans Pedal Assist (sPAS). In terms of Pedal Assist (PAS) this would be Level 0 (L0). The first real climb is at the top of the Gough Road and that saw me move from sPAS to PAS and through Levels 1, 2 and 3 (L1, L2 and L3), and stay there until I had got going up to and into Howick Road where I was able to switch down to PAS L1. I was able to pedal all the way up to the Henderson Road intersection using PAS L1 and then switch up to PAS L3 to get to the Wembley Terrace intersection. That pattern continued and at the end of the ride I had done most of the climbing in using PAS L1, resorting to L2 and L3 for the more challenging climbs. The only problem I encountered was when I was using PAS and did not go into Non Pedal Mode (NPM) early enough to ensure the motor would have cut out by the time I stopped. Also now know as the Halting Problem (HP). I guess I could have tried switching down to PAS L0 as I slowed down. Instead I spent the time think of whether I should fit the braking sensors that immediately cut the motor when the brakes are applied. The kit did come with a pair of mechanical brake calipers that had the sensors built in. Basically a push button switch that is built into the caliper that is release when you apply the brake. The sensors for hydraulic brakes come as a reed switch / magnet combination that has to be glued into position on the brake caliper such that the magnet moves away from the reed switch when the brake is activated and thereby activates the switch. Either way the switch when switched immediately cuts the motor.
My second training ride on the E-bike was my stock Hill 2 Hill (H2H) ride, some 23 kms with an ascent of 620 meters (ex Garmin Forerunner 35). Handled the HP much better and also got the battery down to the last bar (starts with 5). Given that I am hoping to ride the Berg 100, some 100 kms with an ascent of 2200 meters, starting with a fully charged battery and then riding consecutive H2Hs should be a useful tool for estimating my range in terms of a Berg 100 ride.
A month has passed since Bruce and I built the E-bike and I have been for at least three rides per week since then, mostly tackling the H2H ride. I have also managed to get three H2Hs (almost 70 kms) out of a single battery charge. As I originally expected, I will need a secondary battery in order to complete the Berg 100. To that end I have already fitted a carrier to the back of the bike to accommodate the second battery. what remains is to decide on the battery\'s capacity and whether I will want to buy a battery packed with the new format cells that Relectro are expecting to start using to build batteries in the new year (2020).. I also have a scheme that will allow me to fit two bottle holders to the carrier such that they leave the carrier open to either carried a second battery, or the shopping :-) I have also fitted/attached front and rear lights and a small bar-end rear view mirror. Will replace the latter with a larger version as soon as I can source one. Q.E.D., It has been built!
Am I cheating? Me, never. That said it is obviously easier and that has left me better able to once again tackle some of the rides I had started to stay away from. I had to go back to 2015 to find a Hill 2 Hill ride. I still use that route, but don't go all the way to Muswell Hill on the one climb and follow Peter Brown rather than Old Howick / Link Road on the other hill. If you look at the last two pics you will see that I am going up at 10 rather than 5 kph. If I had plotted the graphs against time rather than distance it would also show that most of my ride is still spent pedalling up hill. That is of course to be expected as I am trying to use the battery as sparingly as possible with a view to be ready to tackle and complete the Berg 100. As I have already mentioned, I am also descending the hills somewhat faster, something that I must put a stop to, and certainly not attempt during the Berg 100.
Do it, and if you subsequently find yourself out riding with the roadies training for the Cape Town Cycle Tour, do the right thing and take your turn at the front of the peloton!
Allowing myself to repeat myself?
While I completely bought into Bruce having an e-bike in lieu of not being able to drive, I personally was not that keen on having someone riding the Karkloof Road come past me on an e-bike. That attitude has softened considerably in the face of the extent to which e-bikes have proliferated in other countries, and I have personally seen how that have enabled older people in terms of them being able to get about and even go on cycling holidays. The climate change issue has of course also lent considerable weight to the e-bike cause. It simply makes good sense. Having said that I should add that I have been amazed at how it has not worked out as well as one would have expected in countries like China.
Unfortunately other than in Cape Town where some effort has been made to promote cycling as a mode of commuting, the rest of South Africa does not seem to be interested. Here I believe the government at all levels carries much of the blame. In my own hometown, Pietermaritzburg, almost nothing has been done to accommodate cyclists. Unfortunately it is not much better for the pedestrians with holes in broken sidewalks and the like. The taxi is king and even they come short with respect to potholes and general traffic chaos. For some time now I have believed there is quite a lot that could be done to improve the efficiency of the taxi industry\'s contribution to the daily commute, but that like so many other things plays second fiddle to talking about the latest plan and, "Who knows what they actually do?".
So how does the E-bike ride stack up against the P-bike? In keeping with my expectations and common sense I guess, it is easier, and I can now do rides I had started to stay away from. They also take less time and in a sense that is a plus, more time to pack the dish washer. At this point I should say that the rides I have been doing are with a view to being able to complete the Berg 100, taking less time to do so, and finish feeling less bushed than I normally do. Hopefully I will still do so with a sense of accomplishment.
All of this sees me endeavouring to ride the E-bike making as little use of the PAS it possible in order to stretch the range the a fully charged battery is going to give me. So I use PAS L0 on slight inclines, the level and on down hills this bikes flies. It weighs 20 kgs and that together with my 100 kgs makes for a mean machine. I have to keep on reminding myself that it is not going to be pretty is I come of while doing 45+ kph On moderate inclines I use Granny Gear and PAS L1, and that would be for most of Howick Road. I switch to PAS L2 etc as soon as I feel that I am struggling i.e., dropping below 8 kph. As soon as I feel the need to shift up a gear, I drop the PAS level. Unfortunately dropping into PAS L1 while still climbing can leave you feeling that you are pedaling through syrup.
Both of Bruce'\'s production e-bikes have looked good and performed well. If they did have a fault, it was undoubtedly the electrical connection between the battery (clips) and the contacts (posts) in the battery frame. With normal wear and tear the electrical contact between the clips and the posts started to break and the arcing that accompanied the breaks started to created pits in the posts. With time the pits became larger and this ultimately lead to loss of power and the bike becoming unreliable. Thus far this has not happened with my e-bike, but it is early days.
Where do I think all this leaves me? Thus far I have been more active since I started testing the e-bike. I have also been enjoying the rides more that I would had I been on my p-bike. So I am guessing that this will prolong the time I spend on a bike, both on a weekly basis, and looking into the future. Do I feel that I am cheating in terms of exercise levels. Not at all. The rides are not easy and I know that I am exercising. As to building the bike ourselves, that has certainly been a rewarding experience, one that I would be prepared to repeat.
Money can't buy happiness, but it can buy a bicycle.
If you have any comments, corrections, suggestions or plain criticism, I would appreciate it if you would communicate the same to me.
