377: eBike Project - The Build

The Pedalshift Project: Bicycle Travel Adventures

In this episode, follow an in-depth, step-by-step journey of transforming a surprisingly decent Ozark Trail mountain bike into the first Pedalshift e-bike (n=3 or 4 if you’re counting). This mega-pod takes you from the initial setup to final tweaks, including component replacements, brake and pedal adjustments, and install of a mid drive motor. I’m hardly a bike mechanic, so will things to go sideways at least once like my typical bike adventures?

eBike Project - The Build

• Hey I got an ebike! Where did I end up?
• Decided on build over buy - more flexibility
• Decided on new over used - couldn’t find a good used one that wasn’t $$$
• Went with a Bafang middrive motor and a 52v 20Ah frame mounted battery - smaller than Brian’s, but still pretty big.
• Watched a ton of YouTube videos and bought some tools!
• This took me several weeks because the bike lived at the cabin and I was back and forth a bit as I built it
• This was a journey… and the episode is a little long, but definitely brings you along tour journals style for how it went…

00:00 Introduction and Episode Overview

01:54 Choosing the Right Bike for the E-Bike Conversion

05:52 Initial Setup and Component Replacements

10:56 Challenges and Adjustments

18:05 Programming and Configuration

28:45 Battery Insights and Expectations

41:03 Assembly and Troubleshooting

48:11 Rear Brake Discovery

48:27 Chain Installation Challenges

48:30 Nighttime Reflections

49:27 Final Adjustments and Cable Management

50:51 Chain Sizing Tips

51:47 First Ride Impressions

52:32 Handlebar and Screen Setup

52:51 Rear Brake Issues

55:28 Pedal and Crank Problems

58:54 Cable and Sensor Installations

01:01:44 Tire Upgrade

01:04:14 Battery and Range Concerns

01:04:53 Shakedown Ride Plans

01:07:23 Final Preparations

01:16:47 Shakedown Ride Execution

01:25:48 E-Bike Confidence Boost

01:30:36 Closing Remarks and Future Plans