Rocket Raccoon

Hi again all. Holidays and work have intervened, but hopefully back on the project now. So I have taken out all bearings and purchased replacements. Will start to clean up the frame and parts next, but also need to spec and purchase the motor and associated parts so I can plan the build around. I would very much like to use a front Bafang 250w hub in a road legal set up as per previous posts. Ideally ready built into a polished ally rim as having one laced is going to cost me around £70 at the local bike shop, but all I have seen so far are black. The kits I have seen so far wont really suite either as I need specifics like seperate magnetic motor cut off sensors for the brake system, not new levers, and (the tricky bit) a suitably thin battery with enough power to do 20-30 miles on a charge. (A bit less would be an OK compromise for a slim unit.) So open to suggestions for the parts / battery, any UK dealers you can suggest would be interested for the various bits and pieces? I have been quoted for the slim KinstarBattery 36V 10.5AH with Panasonic 18650 cells $168/pc. and shipping cost of 2pcs to UK $233. Maybe one would suffice. Will it even take the discharge load though? Thanks!

Well, it's out. A bit battered and bruised - and the bike too!

Not tried heating yet, so that's the plan today as the next step thanks!

Thanks! So crank and chain ring should just pull off like the other side so I can get to the other bearing? Its very tight. Might have to get a puller of some sort....

So I got this far by simply unscrewing the LH side of the bottom bracket assembly, surprisingly easily! How does the shaft come out though???

Yep, I may have a crack at it today. Will keep you posted! (Went to a local bike shop to order new headstock bearings and cups this week. He said the same kn the BB. He ended up having a bar welded onto the nut to free it off!

Thanks, will give that some thought. It is already maybe going to be a bit "busy" back there with the gear and brake cabeling though!

OLD = Over Locknut, got it now thanks. Yes looks like you are correct if I want a rear drum. Might need a bit more power from the motor / controller with only 3 speeds though? (Will be used on some fairly gentle hills but also dont want to be peddling like a lune on the flat / downhill.) I guest that also raises another question, front and rear sprocket sizes. Spec for the RD£ says can accept from 13 - 24 teeth?

The plan is to use new rims and renew all bearings - headstock are already out, need to get the bottom bracket apart as a next job, never done that before - all advice appreciated! Ref wheel bearings, front will be a new hub motor and hopefully rear a Sturmy Archer geared hub with brake if one will fit. The distance between the rear drop outs is 115mm, not sure how that translates onto the SA spec sheet attached? (Looking at the RX-RD5)SA hub specs.pdf

Forks are out and seem OK. I'm stripping the frame right back then getting the paint all off too, so far nothing structurally scary

Didn't know that about leaving out a ball, thanks. Top set was quite loose too, suspect water got in hence the rust. Going to bike shop to see if can get replacements today.

Thanks for that. Would several packs in parallel work that being the case?

A bit more stripping today! Stem came out with penetrating oil and some persuasion. Off to the local bike shop tomorrow as there is definitely a bearing issue!

Thanks for this. Ref placement, if this is a suitable battery, I would mount in the Frame triangle sandwiched between two thin sheets of aluminium where a traditional sign would be placed. Controller could go up front still.

Already Googled thanks! As the forks are steel, as long as not too corroded, I should be able to cold set them wide enough thanks

Looking at battery options still. Anyone come accross these? Posted as ebike battery, but look more like they belong in a laptop? Discharge rate suitable for a 250w front hub uphill? http://kinstarbattery.com/Product/45/173

Seat post is out. It is (was) a Brooks saddle

Just took put the front wheel. Looks to be 88mm between the drop outs.

Thats the distance between the fork dropouts? Thanks, will check that.

Will look for pannier batteries thanks

I thought of a rack battery, but would be very obvious. Disguised with a pair of saddle bags maybe? In keeping?

I am hoping to retain the original rod brake lever assemblies and couple to cable actuated disc on the front and drum on the rear. (Some additional bracket work behind the basket will be required.)

On closer inspection the bike has an original Brooks leather saddle. Sadly, probably a bit too far gone to salvage.

Will certainly be checking over and replacing/remanufacturing anything that needs it including brakes, bearings and frame/fork elements that need it.