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2016 townie bbs02

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    2016 townie bbs02

    I've read about the e-grin that happens when you first get on an electric bike. I even imagined what it might be like when I got to do it. Today was that day, and I'm still smiling LOL.

    I bought a 2016 Townie 7D EQ earlier this year with the sole purpose of converting it at some point this summer. I can't remember how many times I bounced back and forth, mid-drive or hub... hub or mid-drive, but I finally decided the BBS02 would be the best fit for me since I really wanted no part of changing a tire that had torque arms. Plus I really like the integrated PAS that comes with the Bafang motors. So a few weeks ago I placed the order with Luna...

    ⦁ Bafang BBS02 750w Mid Drive KIT
    ⦁ Lekkie Bling Ring for Bafang BBS02 - Black
    ⦁ Carbon shark GA 48V

    This was my first build and I'm not terribly mechanically inclined, so there was some trepidation involved. Realistically, I'm probably an ideal candidate for a pre-built bike but I just couldn't get past the fact that everything was so underpowered and expensive compared to what you get DIY. I was pleasantly surprised at just how doable this build was for someone with my skillset.

    2016-07-09 15.15.28.jpg

    The bottom bracket was really easy to take off (probably because it was a new bike) using a bottom bracket removal tool and an 18" breaker bar. The cranks were definitely more difficult, but once I got the crank removal tool threaded properly, they eventually came off. Getting the new cranks on was no picnic either. I don't have a torque wrench but with the same breaker bar I got them tightened down pretty good. I'll check on them from time to time and apply thread locker if they start to loosen up on me.

    I did a test fit on the motor and it fit perfectly in this 68mm bottom bracket. Initially I was a little concerned about crushing the shift cable when locking the motor up in place but it seems this wasn't a problem, it shifts great.

    I would say the most difficult part of the build for me was the battery and getting solid connections from the cradle to the motor. As suggested by many, I picked up the XT90-S pigtails with the intention of soldering one end to the leads coming out of the cradle and the other to power coming from the motor harness. Well, the cheapo soldering iron I bought burned up on me and never got the wires hot enough to apply and solder so I went with the crimp method. For me that seemed to work much better, though I suppose time will tell how solid those connections are.

    20160716_111458.jpg

    I feel a little shaky about how the battery cradle mounts to the water cage bosses. The existing bolts I had stuck up too high and interfered with the battery seating properly. I found some "flatter" head bolts that seem to work okay, but I couldn't use washers or else they could give me the same problem. So I've got an extra zip tie there and some velcro straps when the battery is on and it feels pretty solid for now.

    The carbon shark style battery is an interesting animal. I really like the looks of it over the dolphin or shark. I like that it has the USB port and can be charged on or off the bike. What I'm not crazy about is how finicky it is to get it locked on to the cradle properly. You have to be super careful because it can appear to be seated and you lock it thinking you're good to go, when a simple lift of the handle (or worse, the first bump down the road) will pop it right out of the cradle. I always make sure after locking it that I can't lift the battery out... so far so good.

    Life was pretty grand until I realized the two brake and one throttle cable weren't going to the reach the harness. I'm using mini ape-hangers for a more upright comfortable ride and that extra height is probably why. After my previous soldering adventure, and some good feedback on the forums, I decided that extensions were the answer for me. So I purchased (3) Brake/Throttle extension cables. They're 40" and I didn't need even half of that so I've got some good spaghetti action going on in front that will have to be cleaned up at some point in time.

    20160716_160628.jpg

    So there she is for now. I took it for a test run and climbed this short steep hill in the subdivision like it was flat LOL! Before the conversion I could get up it in 2nd gear at about 5-6mph. With the BBS02 I was cruising up it at 12mph in 3rd gear... what a difference! Using throttle only on flats, I was able to get to 20mph. I've set up the PAS for 9 levels and have only tried up to 4 so far, PAS 2 or 3 is the sweet spot for me at this point. I would guess at the highest PAS and 7th gear I could get 25mph+ if I wanted to. But for me cruising around 15mph is all I really want.

    This was made possible for me by this community. You guys are awesome, Luna is awesome. Thanks!

    #2
    This is so encouraging and exciting to see. It's like taking your best friend and showing them the hidden door to a secret world that all the people around you have no idea exists. I see you already have a Thudbuster seat-post, and a cargo bag. These are the two most useful upgrades to get right away...and you already have them! I put my skullcap helmet and gloves, along with my safety sunglasses near my ebike, but I am making plans for cargo boxes and bags now. Thanks for posting the great pics!

    Comment


      #3
      Yep, the Thudbuster was a nice upgrade. The cargo bag is pretty cool too. It has a lot of room in the main part and the zipper sides to fold out so I can have panniers when needed.

      I'm still working to make it a more comfortable ride. At the moment I can only ride a few miles before my "manly-bits" start getting numb. I may have to get a proper fitting at some point because throwing money at different saddles hasn't worked very well LOL.

      Comment


      • Lance Tesla
        Lance Tesla commented
        Editing a comment
        Based upon the saddle in the picture, you are buying the wrong type of seat for an ebike, especially one with a seating position like a Townie. Because of the assist provided by the motor you do not need to ride bent over for the greatest efficiency and can sit with your spine at closer to a 60* angle. A skinny racing style seat is unsuited to this posture and is best replaced with something that provides a softer place for your sit bones. Numbness is usually cause by pressure on the perineal nerve and can be alleviated by getting a seat with that area cut away. I have had good results from the Selle Royale line.......

      • theronchaplin
        theronchaplin commented
        Editing a comment
        Yeah, I've tried the wide seat (couple different versions, including the one that came with the bike) and they were worse. I would have actual pain instead of just numbness. I'll get it sorted out eventually :D

      • theronchaplin
        theronchaplin commented
        Editing a comment
        I took a look at the Selle Royale saddles and the cut outs are more pronounced than other's I've tried. I ordered a wide one and will let you know how that works :D

      #4
      Good looking bike. Maybe I need another cup of coffee or a few more minutes to wake up but, what is that hub in your front wheel?

      Comment


      • theronchaplin
        theronchaplin commented
        Editing a comment
        The "EQ" version of the townie has a dynamo in the front hub that powers a basic headlight and tail light.

      #5
      I have a wide seat for my Electra (same posture on my Lux frame), no numbness even after long rides. I agree with Lance Tesla, skinny seat is best for a light road bike, where the rider is leaned forward..

      Comment


        #6
        A little spiral wrap and some zip-tie action... looks good enough up front for now :D

        2016-07-17 15.35.48.jpg

        The way this bike is leaning, I see a dual kickstand in my future haha!

        Comment


          #7
          That's a great looking bike! Bet it rides like a dream! I just started a Electra Townie w/BBSHD build for the Mrs's, but she's going to have a tough time keeping me off of it! It is just sooo comfortable! Once the drive is in place it will be one fine magic carpet ride!
          Last edited by Rix Ryds; 07-17-2016, 02:45 PM.

          Comment


            #8
            http://crowcycleco.com/double-leg-ki...ack-extra-tall

            Have this one on Townie and Smoothie, a little tall for a Pure.

            Comment


            • theronchaplin
              theronchaplin commented
              Editing a comment
              That looks like it would work nicely. I'll add it to the list of upgrades! Thanks!

            #9
            UPDATE:

            I've been sticking around close to home until I figure out what kind of range I can expect on the battery (48V Carbon Shark GA). I had initially charged it to 100% and figured I'd be happy with 30-35 miles. Well, at 50 miles the battery was still going strong (I primarily ride PAS 3 out of 9, mostly flat, some short steep hills). For the next 10 miles or so I decided to see what it takes to drain this battery so I ran a lot of throttle and bumped PAS up to 5 (I tried 6 but couldn't keep up pedaling with the motor, yeesh what's 9 like? LOL). Finally after 61-ish miles I figured I'd charge it. I plugged it into the Luna smart charger and it read 48.9V!!! I'm pretty sure that's still 60-ish% battery power left! Needless to say, I'm happy with range. One day I'll ride it out and see how far I can really get.

            Lance Tesla, I picked up a Selle Royal Ellipse saddle and it's definitely the best I've tried so far. Feels like I'm floating on a cloud for the first mile, then tolerable after that. After 5 miles I have some sit-bone pain, but I won't be riding that much at one time very often, plus it's better than the perineum pain I had before. Thanks!

            Also I'll add that I've been able to get to 25mph throttle only in top gear. The 20mph I stated earlier must have been in a lower gear, probably 3rd or 4th. That said I'm quite comfortable cruising around at 15mph on this style of bike. Things feel a little uneasy to me at 20mph and up.

            Comment


              #10
              Originally posted by theronchaplin View Post
              Life was pretty grand until I realized the two brake and one throttle cable weren't going to the reach the harness. I'm using mini ape-hangers for a more upright comfortable ride and that extra height is probably why. After my previous soldering adventure, and some good feedback on the forums, I decided that extensions were the answer for me. So I purchased (3) Brake/Throttle extension cables. They're 40" and I didn't need even half of that so I've got some good spaghetti action going on in front that will have to be cleaned up at some point in time.

              I feel the Electra Townie 7D might be one of the best Bafang Mid Drive bikes to build up.

              I built up recently an Electra Lux Fatt 7D and like it also. But there are things that I know now after riding and transporting it a bit. First the Lux Fatt 7D is heavier than a Townie 7D (if you have to lift it into the back of your truck). And secondly, it is less stealth, so it catches peoples eye more when the see the fat tires (I do like the idea of being more incognito)

              I'm glad I found your post with the Mini Ape Hanger handlebars. I was considering them as I would like the grips to be higher and furter back on the Lux Fat 7D . But I must honestly say that looking at your bike with them I prefer the look of the standard Lux Fatt 7D beach cruiser type handlebars, as they have the more classic beach cruiser look.

              But my feeling is that on these forward pedal bike the the grips should almost be right over the crank and at least belly button high when you sitting fully upright (back straight). This way your arms won't be totally straight when sitting fully upright. I feel your arms should be bent and relaxed when sitting fully upright. As there is no need to be hunched over with a Mid Drive right?

              So I'm considering adding a stem extension, or finding a longer stem, and possibly even turning the stem around with a stem extension and just keeping the stock Lux Fatt 7D beach cruiser type handle bars.

              But even with my stock Lux Fatt 7D handle bars I'm still in need of wiring extensions also :-( They need to make a BBSHD kit for beach cruiser type handlebars, making them longer or even letting us have the option of cutting them down in size and re-splicing if needed.

              Comment


                #11
                I liked my build a lot until a few of you guys started building up the Lux Fatt's... the grass is always greener LOL.

                Regarding the handlebars, I guess I've never measured anything but it's a very comfortable riding position. My arms are certainly not locked, and being upright I don't have the weight bearing down on my forearms/hands that gave me chronic pain when I had a more aggressive riding style bike. But if aesthetics are a thing, then yeah try the stem extension thing (though I would caution against turning it around, you lose a lot of control that way.)

                Comment

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