Calibre Bossnut with Tongsheng TSDZ2

[Paultig]

Hi,
Just finished my 4th conversion with the Tongsheng TSDZ2 500w motor kit from PSW Power. I thought you may be interested to see it as I couldn't find any when I searched. I had bought 2 kits for me and the wife, originally fitted to our Boardman Team Hybrids which work really well but i decided to switch the kits to our Calibre Bossnut MTB's. It looked like a bit of an awkward fit at first due to the lack of chain stay triangles at the base of the seat tube which serves as a mounting point for the torque bracket and the large 14A battery mounting but both overcome with what ended up as a neat install.

 

[jmlflorencio]

Great. I'm eager to get my hands on one of those kits. How's the ride?

I like that battery case, it looks like it was made specifically for that frame. But... Won't you have a problem securing it upside down? Will it hold?

 

[Paultig]

Great. I'm eager to get my hands on one of those kits. How's the ride?

I like that battery case, it looks like it was made specifically for that frame. But... Won't you have a problem securing it upside down? Will it hold?

It rides really well, i like the torque drive which means you have to put in some effort then the motor multiplies the effort, 500w and 48v gives me over 30mph i haven't fully range tested it yet but 14amp should give me plenty. The whole kit only adds 7kg. For some spirited off road I will assist the two battery support bolts with some strapping but i won't be going mad.

 

[Eltommo]

Hi, I bossnut same as you and unfortunately was diagnosed with a lung condition which meant my bike never got used. However I am improving after recent medication and docs say to get out and exercise. Converting my bossnut would be great. Can you please tell me what I need to buy as a friend said he can do the conversion and hopefullyI can enjoy my bike again. Yours looks wonderful. Thank you so much

 

[Eltommo]

Is this the kit you used? Are able to tell me what was the problem you encountered and how did you fix it? Thank you Tom

 

[Crazylegs1892]

Hello

I've got a Calibre Bossnut myself. I've thought about this kit as an option, Woosh bike sell a battery bag kit and I have a local company that can install it for me. My only concerns are taking the bike through water.

I did a red trail recently and it was heavily waterlogged in places which meant cycling through some deep water. I'd have concerns that submerging the bike would ruin the mid drive motor. Have you taken the bike through water at all? Also does the kit add a lot of weight to the bike?

Many thanks

Marc

 

[pxl666]

i would go for a 36t NW chainring and 50t casette to make life easier . also i'd secure the battery with strap when going mtb .
did you use rubber washers for hailong rail to secure if from side wobbling ?

 

[Crazylegs1892]

i would go for a 36t NW chainring and 50t casette to make life easier . also i'd secure the battery with strap when going mtb .
did you use rubber washers for hailong rail to secure if from side wobbling ?

Thank you for the advice. Does the 36t chainring and 50t cassette reduce and shorten the gearing? It's 1x12 set at the moment that comes as standard on the Bossnut but from what I've read, if you have more gears it'll mean more stress on the chain?

I'd have thought the battery would be secure anyway wouldn't it? How would the battery pack work with a dropper post when doing downhill sections and undulating terrain?

Cheers

 

[Crazylegs1892]

Just to add. I'd have thought have more torque going through the pedals would actually provide less stress on a chain? Similar to a Turbo on an engine, it provides more torque lower down in the rev range at various gears, so less stress on the chain?

 

[pxl666]

the bigger casette and smaller the chainring the better and less stressful for entire drive and motor

 

[Bikes4two]

That @Paultig is a very neat conversion. On the battery support matter, rather than straps, have you considered adding rivnuts to the frame?

Obviously an ordinary drill won't be able to line up with the underside of the frame but maybe a small right-angle adapter will do it?

I bought one of these from Screwfix and successfully installed rivnuts for mounting a bottle cage on an awkward part of the frame.

 

[Crazylegs1892]

How have found doing rough terrain and trails with this kit, does it catch big stones more easily as the conversion is much bigger on the bottom bracket than the standard setup isn't it?

 

[pxl666]

How have found doing rough terrain and trails with this kit, does it catch big stones more easily as the conversion is much bigger on the bottom bracket than the standard setup isn't it?

you obviously have to be more careful...I've done many mtbs and they do a good job proven the rider knows his stuff

https://photos.app.goo.gl/wUW1Q5fqZ4vT7LBQ7

 

[theWoosh]

Hi @Paultig or anyone else who has done this - I am looking at a second-hand calibre bossnut Evo and want to fit a 36V mid-drive motor like a BBS01 or Tongsheng TSDZ2B - Were there any issues I would need to be aware of?
I have read that this bike has a press-fit Bottom Bracket and the motors all work with screw fit - if this is the case did you have to use an adaptor and has that proved to be a stable fit? Any adaptions needed to get the chainline right?
Any info would be most gratefully received - I don't want to get the bike and find I can't fit the motor.
Many Thanks
Correction - I now think that the bike has a BSA threaded 73mm BB which makes things easier...

 

[saneagle]

Hi @Paultig or anyone else who has done this - I am looking at a second-hand calibre bossnut Evo and want to fit a 36V mid-drive motor like a BBS01 or Tongsheng TSDZ2B - Were there any issues I would need to be aware of?
I have read that this bike has a press-fit Bottom Bracket and the motors all work with screw fit - if this is the case did you have to use an adaptor and has that proved to be a stable fit? Any adaptions needed to get the chainline right?
Any info would be most gratefully received - I don't want to get the bike and find I can't fit the motor.
Many Thanks

His photos don't show how he arranged his motor to resist the torque reaction. I think it's very dodgy doing it like that. If you don't use the provided arrangement, you need to fabricate your own torque arm or some other way to resist the torque. I've seen one of those motors with a cracked case because the owner thought he could let the motor rest on the downtube to prevent it rotating around the BB, but the leverage was too much for the casing.

The latest version relies on friction on the bottom bracket tube to resist torque. I wouldn't trust that on a normal BSA/Shimano BB, but it can't work at all on a PF BB because there's no way to lock it.

Also, that battery arrangement might be OK for dry riding, but it's going to fill up with water if your ride it in any sort of wet conditions. Those batteries need to be mounted the right way up because the water that lands on the top (when it's mounted like OP's) will be channeled directly to the connector, through that into the cell-pack, with no way to get out, so it'll continue to fill until boom!

 

[theWoosh]

Many thanks for reply @saneagle - I have a different battery setup strategy so not worried about that but I am not clear (as I'm not familiar with mid-drives other than the Cyclone), how OP has had to diverge from standard motor fitting - does his model use a Press-Fit BB? (the one I am getting has a standard screw). It would be really useful to know what I'll be up against as I was planning to buy the bike this afternoon if it's suitable. Any detail gratefully welcome!

 

[theWoosh]

... I presume as it has screw BB I can just use the supplied friction plate...?

 

[Peter.Bridge]

I know this is for bafang mid drive motors, but basically recommends 2 specific press fit adapters PF30 to BSA and BB30 to BSA. Once the adapter is fitted (so its now a BSA bottom bracket) I would think the TSDZ2B would fit

( I have that adapter PF30 to BSA on my Bafang BBS mid drive bike and its been working fine for several years)

Bottom Bracket Standards and Bafang mid drive motors

Will the BBSxx fit in my bike? This is a question that many of us need help in answering. The question you should be asking first is "what kind of bottom bracket does my bike have"? You need to know the answer to this in order to understand how the BBS02 or BBSHD will fit in your bike and what...

www.empoweredcycles.com

 

[theWoosh]

@Peter.Bridge I am out of my depth here - I thought the bike cam e with a 73mm screw fit BB - why would I need a press fit adaptor? Sorry I'm confused as hell over this...

 

[saneagle]

... I presume as it has screw BB I can just use the supplied friction plate...?

Screw-in BBs are locked when installed. PF ones will rotate due to the reaction torque of a motor. You therefore need a separate arrangement to hold the motor stationary when using PF BB. That's easy to achieve on some bikes using spotlight bracket and torque arm like in this photo:


The friction arrangement for a normal screw-in BB is probably OK for a BBS01 or TSDZ01, but I wouldn't trust it for one of the modern high torque motors, like TSDZ8 or BBS02. That torque arrangement costs about £3, and it gives you extra security. If you read back through all the threads about people fitting crank-motor kits, you will see that virtually all of them came loose soon after fitting, and they needed to be re-tightened. Most of the time that's not really a problem. The motor will rotate until it can't go any further, like when it rests on the downtube, but as I said earlier, on some bikes, the geometry causes huge leverage on the motor casing, which is not designed for loads in that direction. Read all about it here. This is one of many examples:

My TSDZ2 casing broke. Are shell replacements worth it or should I consider other options?

My TSDZ2 cracked down the center while climbing a steep hill. This caused the gears to separate enough that they could no longer grip each other. If you're wondering how on earth this happened, I have some guesses but I'm no engineer. For one, I left it out the "fixing block" since it didn't...

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