Building first electric bike (folder) - any advice is appreciated

alex_

Just Joined
Jun 22, 2013
1
0
Hi,

For last 2 weeks I've been reading about electrical bicycles, conversions, etc and became quite obsessed with the idea of building an electrical folder myself. I cannot really throw this idea out of my head :p

My wife needs to commute to work up to 11miles per day and she asked me about an electrical folding bike. The place where we leave has quite a lot of hills, so the bike should be a quite good hill climber.

I am thinking about building an electric folder from one of the following bikes:
Tern Link D7i
Dahon Vitesse D3
Dahon Ciao D5

All of the selected bicycles have inner hub and I am going to do a front conversion. My rational for this is that inner hub requires less maintenance then derailleur ( I am really bad/lazy with doing maintenance). Also, a bicycle with inner hub looks cleaner when taking it into a public transport. Perhaps, the last statement is very subjective and arguable :)

Dahon Vitesse D3 seems the most appealing to me due to its low weight of 11.9kg (published on Dahon site) but I am a bit concerned by its 3 gears. IMHO, it should be Ok for electrical bike and I do not think that my wife would ever need more gears whilst cycling in a city traffic but may be I am wrong, as I have not owned folder before. I would really appreciate if anyone could advice me about the optimal number of gears for electric bicycle with pedal-assisting mode in city traffic conditions.

Also, the selected Dahons bicycles forks are made from INTEGRATED PATENTED FUSION TECHNOLOGY. Does anyone know whether it is a special kind of steel and is it Ok to use them with front hub motor?

After some researches (including reading this forum) I found that a conversion kit from greenbikekit.com seems like meeting my needs: 36v 250w 85f v-brake electric bicycle kit. It fits into 83mm fork drop-outs and it waits only 1.6kg.

I am thinking about buying a li-ion battery 36V 9Ah. It looks like 9ah should be Ok but I am wondering whether I should go with 11Ah battery. I am more worrying about hill climbing rather then having bigger distance to go on a single charge. It looks like 11Ah should also give more power to the motor but I am not sure about it.

Another battery I am also considering is 36V 10Ah LiFePO4 but it is heavier then the first one on 1.3kg and I would like to keep bike weight as low as possible.

Unfortunately, this version of the kit is not coming with the mounting instructions but I suppose that they should be quite similar to the instructions coming with cyclotricity conversion kit here or video instructions for ELFEi Conversion Kit

Please, correct me if I am quite naïve with this assumption and the things are not really so simple as they look like:)

At the moment, the only thing unclear for me is how to mount a battery into usual bicycle rack? Should I purchase a special rack with a battery compartment in order to increase the reliability of battery fastening? If so, has anyone tried to fit on 20” bike the rack for 24” wheel from greenbikekit ? I just do not want to have another order from China having a rack only. I could not find any place in UK to buy such a rack.

If I go with Dahon Vitesse D3 and without buying a special rack I might get an electrical bike with weight of 17-18kg (taking that Vitesse D3 waits 11.9kg) but I am not keeping my hopes high about it:)

I am expecting in result of conversion to get an electrical bicycle capable of cycling up to 30 miles on a single battery charge. The approximate mileage per year will be around 1500 miles. I assume that the bicycle will serve at least 2-3 years without any need to replace any electrical or mechanical part.

I greatly appreciate any advice or/and suggestion w.r.t. GTK conversion kit and the folding bicycle front wheel conversion.

Kind Regards,
Alex