Davoman

more to support a basket, I am using a similar approach to StuartsProjects, of an aluminium L bracket, but to support either a basket or small box like below. and just sit the batter/controller bag in it alongside shopping bags etc. I dont fold the bike much so thats not an issue. when the front wheel flops it does catch the brake cable slighly so i may need to extend the cable or protect it somehow. below is a photo of a pretty gruesome prototype:

The kit is this from TopBikeKit https://www.topbikekit.com/16kg-tbk74ad-36v250w-48v250w-front-motor-with-20inch-406-wheel-rim-for-bromptoncranstondohon-bike-p-1320.html?zenid=lenkm5kptcedokqotuugtavks5 I went with the standard components: the motor is, I think an AKM 74, 250w, with LCD4 display, kt controller, and yes had brake handle and cut-offs and throttle, the lightest battery which is 36v10ah, and no torque arm. I did install the cut-offs and throttle. As mentioned elsewhere in this thread, the torque sensor had just failed on my bafang mid-drive bike. This meant that sometimes the motor did not stop when i stopped pedalling, which was a bit scary when approaching an intersection. So, i decided to take the low-risk option and install the cut-offs even though they arent essential. I put the throttle on just to see if it added much usability. Ideally, i'd like to have the throttle set to cut out at say 6kph, but there doesnt seem to be an option to have different top speeds between the throttle and PAS. So the top limit across both is the legal 25kp. I may remove the throttle (easy to do, just unplug) as occasionally I bump it when moving the bike out of my garage etc, causing unexpected start. As with a lot of projects i probably spent 6 months deciding, 6 weeks for delivery and 3 hours to actually assemble the thing. And a lot of time measuring the size of drop-outs etc. Also, although the Dahon folds, I rarely do this, it was just the first 20" bike I saw, in good condition, and with a nexus 8 IGH which I like. Ordering was straightforward, with pretty good communication with the site. They seem experienced with the quirks of builders. Note prices are in USD. Shipping to Oz was a bit pricey as to keep things simple I ordered the battery from them as well. Everything came in one box, well packed: There was a slight glitch with the shipping, the kit seemed to arrive in-country quite quickly , then sat at a local warehouse for over 2 weeks. When I followed up TBK said the delay was due to 'random custom inspection' - which seemed odd - and it was despatched to me the next day. despite requiring a signature the box was just left at the front door, which was a bit of a worry as we have had a lot of delivery theft locally. Assembly was surprisingly easy. I'd read it only took an hour or so, and the instructional video is just 10 minutes long ( https://www.youtube.com/watch?v=Rb0OSOdkqM0 ) but it was very easy. The trickiest part was actually the 'non-electric' elements, as I've done very little work on bikes since my teens. So, removing/transferring my old tyre, taking off handlebar grips, removing existing brake levers, installing the new levers and fitting the cable ends into the levers, then trying to re-align the brake pads, was the trickiest and most time consuming part, and I will take the bike to a local mechanic for a quick QA and check i puy everyhing back in the right way. I also stared at the PAS sensor etc working out which side to put it on, would i need to trim it to fit (see the video for this) but in the end the two sides of the PAS just pushed together quite neatly, then fitting the metal ring to hold the two parts was pretty easy. I would be surprised, however, if the PAS magnet ring gets a bit loose over time, as it is only really held on by friction, so some expoxy may be need. The battery/controller bag is also a bit fiddly to squeeze everything in, and cable management is still a challenge. But again, once motor and brake levers were in, the connections just took 5 minutes. As promised by TBK, the controller came configured. But the PAS is a bit jerky on/off, so I asked TBK for the manual and they sent the link http://topbikekit.com/LCD4%20display.pdf and will adjust settings to make take-off a bit smoother. I also have two washers left over, as I couldnt work out where they fitted. Below is a snap of the front wheel, is anything missing? Next steps are to customise the useability of the bike, putting on a front rack/box/basket to get more weight over the front wheel. there is a little bit of wheel spin currently if i set the PAS above 2 or use the throttle too heavily. Also move the battery back down a bit, possible sitting in or on the front basket installing a twin-leg stand putting on a small spring on the front wheel to stop it flopping so much more comfortable handlebars and saddle, as I ride it very upright. Note I have already put on a handlebar extender to lessen the crouch Compared to my heavier mid-drive, this feels much quicker, even without power, maybe less rolling resistance due to the narrower tyres. Its hard to judge battery distance, but it will be relatively less, which is fine as I use it for short trips to the shop, and Im happy to charge it a couple of times a week. Pushing up a hill on PAS 5 throttle really hits the battery. Below is a photo, while waiting for a ferry, and the smaller wheels/wheelbase make it much easier getting on and off. Happy to answer any other questions, and thanks again to those who helped with advice.

Yes! One reason i did the conversion is that my other bike (Velectrix small step through with a bafang mid-drive 18 months old) developed a fault with the torque sensor which could apparently only be fixed by installing a new motor. The whole Dahon bike+kit cost less that the quoted cost for the replacement.

Well that is a bit of a story. I want to mount a front rack or box and I was a bit worried that the existing mount wouldn't quite be strong enough to support a box and stop it swinging from side to side. So I mixed up some epoxy putty and then put that around the mount and evened it up so that there's a larger area supporting the Box once I screw it in using the existing mount. I also may use a couple of u-bolts to hold the Box top and bottom

TBK kit, it all went straight forwardly and happy with the results, a light, zippy ebike. Thanks to all here for the tips and advice

Hi, about to get one of these for my dahon ciao and had a few questions: - is it worth getting a bluetooth BMS? - if i get a motor for 74mm drop outs, can this be later moved to a bike with 100mm drop outs, using some sort of spacer arrangement? - there is an option for 'bullet' plug, battery connection, is this ok? thanks for any insights DM,

HMM, have put a direct link in, now

Sorry forgot! I just found this on AliExpress: AU$1,119.98 | MACFREY Brompton E-Bike Conversion Kits E Bike motor Kits 36V10AH Battery,Bike to Electric Bike Upgrade Kit 250W 16 inch wheel https://a.aliexpress.com/_mKkqBLZ

Has anyone looked at these? They seem a bit better designed than the top bike kits EDIT:SORRY FORGOT THE LINK https://www.aliexpress.com/item/1005008704048315.html

excuse my ignorance, but how do i measure the inner rim width? presumably remove the tyre ? I couldnt see any markings on the rim itself. also, if i do this, does the outer rim width change too, and so affect brakes?

Thanks I’ll have a look

HI All Greetings from the land downunder I recently picked up a Dahon Ciao which I'd like to convert as it is : very light, seems well made and has Nexus 8 IGH (which i prefer to deraillier) and in particular a very low step-through. It will just be for short trips (1-2km each way) to the shops etc, with some moderate hills. Not looking for ultra speed just make things a bit easier on my 75kg 67 y.o. knees. So, Im hoping for advice on: 1. a good, reasonably priced kit, eg this one: https://topbikekit.com/16kg-tbk74ad-36v250w-48v250w-front-motor-with-20inch-406-wheel-rim-for-bromptoncranstondohon-bike-p-1320.html?number_of_uploads=0&zenid=k0fjrkpag0ippfr4rr7466lbi5 . it has the 75mm drop out.s 2. any tips on doing the conversion? I've a basic understanding of ebikes, already having a Velectrix step-through which is good, but just a bit heavy 3. will i need a torque arm? front forks are steel 4. current tyres are 1.5", they are ok but was thinkng of moving to 1.75" (rims are 406) and any other suggestions very welcome!