My New Build

[Waspy]

That looks brilliant. I'm going to do another one for my eldest son later in the year, I will nick that idea

Mate, it took a lot of jiggery - pokery with nuts and bolts.

That red bracket can take one of these:

Which opens up a whole world of Brompton attachment possibilities, like this:

These things are addictive, this one is an hour from me, I keep trying to do man maths to make it a good idea to get it for my granddaughter.

 

[Waspy]

OK, say back to the front axle nuts.

This was the way they were, the flange on the nut is 24mm and there is no way it will ever go inside the lips on the fork drop-outs, even after filing the drop outs to get the axle central.

As you can see in this picture the nut flange was only really tightening against the front of the lips, which simply harmlessly deformed the steel (like saneagle said it would).

That would probably work if you had the nuts tight enough, but I wasn't happy.

So I got the dremel out and cut back and reshaped the deformed lips a bit.

Next I got some M12x20mm washers. These are not easy to find, standard size is M12x24mm.

They don't sell them in Screwfix etc.

I got some from here:

So now the washers sit nicely inside the lips. and the pressure from tightening the nuts will be flat and even.

Next came the nuts, research showed that bike M12 nuts are different to standard M12 nuts. Standard have a coarse pitch of 1.75, bike nuts have a fine pitch of 1.25.

These are easily found by searching eBay for M12x1.25 nuts.

Incidentally, the new nuts need a 19mm spanner, not 18mm as on bike nuts.

So these are them fitted, with everything inside the drop-out lips and the ant-rotation washers nicely deep in the drop-outs.

I understand that the flanged nuts spread the load better, but I wasn't happy that they were not sitting flush. And these nuts are going to be tightened up very tight.

 

[Waspy]

I finally got my battery, LCD5, PAS and other stuff from Topbikekit.

The battery, controller and cables fitted easily into my camera bag. Actually the bag is really too big, I had to stuff quite a bit of padding in there. I will be keeping my eye out for something smaller, certainly narrower anyway.

I took my time and went through all the P and C settings on the LCD5.

I found this guy's video very helpful.

So that's it, job finished, apart from a couple of little things I have to tidy up.

I took it out for a test ride and the everything works great, I didn't even notice the weight of the battery over the front wheel.

Top speed was about 17MPH, same as on my Trek. Power transmission very smooth. Hill-climbing felt very strong. The riding position was comfortable but the lack of suspension over rough(ish) ground was sorely missed, best to keep the speed down to 12 or even 10MPH over rough ground. This is definitely a tarmac bike, flat, off-road gravel paths are OK, as should be towpaths.

Cost breakdown:

Bike £100
Yosepower motor wheel and other stuff £134
Topbikekit 15AH battery, KT controller, LCD, PAS plus a couple of other odds and ends £345
Tyres £20
Hydraulic calipers £24
Odds and ends, nuts, bolts, washers, brackets £30

Total £653

 

[Waspy]

Did you notice the on/off power that I mentioned above?

Now I've compared them back to back, yes definitely.

In the LCD5 settings I set C5=00 this gives a smooth increase of power, instead of all the power instantly.

 

[Peter.Bridge]

the lack of suspension over rough(ish) ground was sorely missed, best to keep the speed down to 12 or even 10MPH over rough ground. This is definitely a tarmac bike, flat, off-road gravel paths are OK, as should be towpaths.

That's brilliant !

It will fit quite wide tyres, that you could run a lower pressure. I have 2.15" ones on the one i did for my son.

I was wondering about these for the one I am building for my elder son ?

https://winstanleysbikes.co.uk/maxxis-minion-dhr-ii-20-inch-clincher-tyre?

 

[Waspy]

That's brilliant !

It will fit quite wide tyres, that you could run a lower pressure. I have 2.15" ones on the one i did for my son.

I was wondering about these for the one I am building for my elder son ?

https://winstanleysbikes.co.uk/maxxis-minion-dhr-ii-20-inch-clincher-tyre?

Thanks mate.

I bought those tyres in huff because the day my 2.15 tyres (I was copying you) from eBay were supposed to turn up, I got a message saying "Sorry out of stock, refund issued" So I jumped in my car in a strop and went to Halfords and bought those BMX tyres for 10 quid each.

Yes, I could definitely lower the pressures a bit.

Those tyres you linked have quite an aggressive tread for a 20" wheel!

Size says 20x2.30, do you think those would fit? Let me know how you get on please.

 

[Peter.Bridge]

Have you got a luggage scales (the ones with a hook on them that you attach the luggage to )

I predict 19kg including the battery

 

[Waspy]

Have you got a luggage scales (the ones with a hook on them that you attach the luggage to )

I predict 19kg including the battery

No, I'm afraid I own no such scales.

Your experience with these bikes suggests your prediction could well be right.

But, I have no problem lifting 19kg into my car, or 16.6kg if I unplug and remove the battery, it's just one XT60 connector.

In other news this bracket from Aliexpress arrived today:

The bolt holes are elongated, which means it will accept bolts 30mm apart, which means it fits the Carrera, which means it opens up a whole world of Brompton style bags etc. which can be simply clipped in place.

 

[Nealh]

Keep an eye on the controller temp , it will need some free air around it and not to cosset it up in padding.

 

[Waspy]

Keep an eye on the controller temp , it will need some free air around it and not to cosset it up in padding.

Noted, thank you.

 

[matthewslack]

If the suspension comfort issue is the seat end, not the bars end, then a proper suspension seatpost will solve it. Suntour NCX, about £90, I wouldn't go back to a cheap one now!

 

[Waspy]

If the suspension comfort issue is the seat end, not the bars end, then a proper suspension seatpost will solve it. Suntour NCX, about £90, I wouldn't go back to a cheap one now!

The lack of suspension is not really an issue if you use the bike for what it was designed for, tarmac, towpaths, compacted gravel paths, cycle paths etc. It is not a mountain bike, but I knew that when I bought it.

I have a Suntour NCX on my mountain bike and I agree it is pretty good, however the NCX seatposts are not long enough for a folding bike. Or fat enough come to that, my Carrera seatpost is 40.1mm

 

[matthewslack]

Good information! You have exposed my non-folding status comprehensively!