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Surly ECR Expedition Bike 750w BBS02 Mid-drive

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    Surly ECR Expedition Bike 750w BBS02 Mid-drive

    I decided to pull out all of the stops with this E-bike build and use all top shelf components which have proven to be tough and reliable. The end result, in my opinion, is a sturdy yet simple expedition bike which is easy to repair in the field and disassembles quickly for transportation by plane or ship. It sports a dynamic hub generator to operate lights and to charge accessories. S&S couplers are used in the frame as well as cable separators for ease of disassembly. I opted to use the 29+ platform with semi-fat tires for use in a variety of conditions from soft snow to marshlands and everything in between. Multiple attachment points were required for racks and water cages and a durable powder coat finish was added for frame protection. The handlebars needed multiple hand placement positions and to be wide enough for good control on rough surfaces, so I chose the Jones H-bar which also has a perfect cross bar to hold the C961 1000 Display.

    I started this bicycle build with a new Surly ECR frameset which I commissioned Bilenky Cycle Works in Philadelphia, PA to retrofit S&S couplers to. Then it was sent out for a custom metallic black powder coat and then shipped to me ready for the build. Next I installed a Chris King headset and Luna BBS02 750w Mid-drive electric kit in place of a standard bottom bracket. Adding Thomson Elite X4 stem and Jeff Jones H-Bar Loop handlebar came next along with a Rohloff speed shifter and E-bike brake levers. I used a Thomson Setback seat post with a Brooks Cambium C15 vulcanized rubber saddle for weather proof riding. Avid BB7 S mechanical disc brakes were mounted with 160mm rotors and Jagwire compressionless cables. The drive train consists of a Rohloff 500/14 SpeedHub using a 16T cog mated to the BBS02 Crankset using a Surly stainless 34T chainring. The wheels were laced with black DB Wheelsmith spokes and nipples on black Velocity BLUNT & DUALLY rims. For a front hub I used a black Shutter Precision PD-8 6V3W dynamo with 36 holes. In the rear I used a black Rohloff 500/14 Hub also with 36 holes. I then wrapped these 29” wheels in a pair of Surly 29×3 Knard tires officially turning this bike into a 29+ E-Bike. The addition of a Surly Nice Rack in the back and a pair of Salsa Downunder Racks up front with a side of Salsa Anything Cage HD hanging off the left fork rounded out this expedition build. Finally I hooked up the lights and attached some Ortlieb waterproof panniers and this bike was ready for a serious adventure.

    I have just recently added a Bafang Gearsensor by Luna Cycle which works flawlessly with the Rohloff internally geared hub. Prior to this new install, I had to pull back on the brake levers slightly before shifting to keep from putting too much strain on the chain and gears. The Gearsensor causes a slight pause in the Bafang motor while the Rohloff shifts smoothly into another gear.

    How does it run?

    I live in the US Virgin Islands so there are two types of riding conditions, flat waterfront & extreme hillclimbs. On the flats the bike travels easily at 32mph and even the most demanding long hills 14-16% grade can be climbed at 12mph or faster. I purchased one of the earlier BBS02 units and had a little trouble with it overheating on long climbs. Last month I switched out the controller with the upgraded 25 amp mosfets controller and now it doesn't even get warm under the most grueling workout. I'm using a Luna Cycle TRIANGLE 52v Panasonic PF 18650 20ah Pack Battery which gets between 35 and 50 miles per charge. St Thomas island is only 14 miles long so I usually charge the pack once a week.

    In my opinion, the BaFang Mid-drive motors coupled with a good IGH (Internally Geared Hub) such as the Rohloff Speed Hub is the ideal platform for an E-bike.

    Here is the complete build list:

    SURLY ECR BUILD

    Manufacturer / Model

    Surly

    Frame and Size

    • ECR – Size Medium

    • S&S Couplers retrofit

    • Custom Powder Coat (metallic black)

    • Headset Chris King 1-1/8"

    • Luna Cycle BBS02 BaFang 750w Mid-drive Electric motor

    • Luna Cycle TRIANGLE 52v Panasonic PF 18650 20ah Pack

    • Luna Cycles Triangle Frame Bag

    • Surly Stainless 34T Chainring

    • Kmc Bicycle Chain “X-1 For Rohloff” 109 link Dyna-sys compatible 275 grams

    • Jagwire Pro Mountain Brake Cable Kit

    BAR – SADDLE – BRAKES

    • Luna Cycle E-bike Brake levers
    • Avid BB7 S Mechanical Disc Brake Front and Rear
    • Avid G2 Cleansweep Rh Disc Rotor Rohloff 160mm

    Handlebar & Stem

    • Thompson Stem Aluminum. 4-bolt face.
    (10 degree angle, 120 extension, Black)

    • Jeff Jones 660 H-Bar

    • Shifter: Rohloff Twist Shifter

    • Grips: Ergon GC1

    Saddle

    • Brooks Cambium C15 Slate
    (waterproof cotton & vulcanized rubber)

    Seatpost

    • Thomson Elite Setback Seatpost

    Lights

    • Headlight – Herman’s 50 Lux Headlight

    • Taillight – Herman’s H-Track Ultra-bright Taillight

    • E-werk Dynohub Power Converter for charging cell phone etc.

    • Anker External Battery

    • Wiring harness for lights
    (Schmidt part coaxial Fly type 1.9m w/con)

    • Supernova gold plated wiring connectors

    Wheels

    Front

    • Front Hub/Wheel: Precision dynohub (black),
    laced to a 36-hole Velocity BLUNT rim (black)
    with Wheelsmith DB 14-guage spokes (all black).
    • Front Tire Surly Knard 29×3
    • tube Surly 29×3

    Rear

    • Rear hub: Rohloff SPEEDHUB 500/14 TS DB OEM2 black
    36h ISO (black) laced to a 36-hole Velocity Dually
    rim (black) with Wheelsmith DB 14-guage spokes (all black).
    • Rear Tire Surly Knard 29×3
    • tube Surly 29×3
    • Surly Tugg Nut
    • Ritchey 29er Rim Tape

    Pedals

    • Shimano A530 SPD Dual Platform Pedal

    • Locking Axle Skewers

    Panniers

    • Ortlieb Bike Packer Plus (Hazel)

    • Ortlieb Ultimate 5 Plus Medium Handlebar Bag (Hazel)

    • Thorn Accessory Bar MK1

    • Ortlieb Map Case

    • Ortlieb Front Roller Plus (Hazel)

    • Ortlieb Classic Saddlebag (Black)

    • Salsa Down Under Front Rack

    • Surly Nice Rack rear

    • Water Bottle Cages x 4

    • Salsa Anything Cage

    • Bike Buddy Fuel Bottle Rack

    • Da Vinci cable splitters

    • Extra cables for splitters

    • steering tube spacers

    • S&S FINISH LINE GREASE 20g

    • S&S SINGLE SPANNER WRENCH

    • SURLY Bolt-On Seat post Clamp

    #2
    Just found this thread. Well put together thread. Thanks for posting.

    Comment


      #3
      Wow! Let's see some pictures of the whole bike.

      An ECR Speedhub BBS02 was my first thought when I started planning my custom build, but I ended up with a Soma B-Side V.2 Belt Drive Strumey-Archer 3spd BBS02 in the end. I'm into it for over $3,000 and if I went ECR & Speedhub I'd over $5,000.

      I bet it is beautiful to look at and ride.
      MOVING BACK TO PEDAL...
      2020 Banshee Paradox V3 1x11 (pedal)
      2018 Soma Wolverine 3spd IGH Belt Drive (pedal)

      Comment

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