Electra Lux Fatt 7D BBSHD installation

[g725s]

First, cut off the chainguard tab:



Then use hammer(s) and heavy steel round to dimple down-tube and seat-tube. I used mostly the steel round to indent the down-tube and the ball pein hammer to indent the seat-tube:



Install BBSHD into triangle side of frame :



In the picture above you can see the allen head screw of the mounting tab to the right on the BBSHD. I had to file down the corner of that tab just a bit.

Next is to cut the Bottom Bracket down to around 70mm.

[g725s]

Here is another picture of the indents:

[g725s]

Here is a picture of the BBSHD before I filed the corner of the tab with the allen screw:


I did buy this Nicholson file for aluminium: https://www.amazon.com/Nicholson-Alu.../dp/B006P2XB4E I might have taken 3/32" or 1mm off the corner of that tab.

[calfee20]

No worries about your motor rocking back and forth with this installation.

[calfee20]

Nice job, your frame looks like it was molded around the BBSHD. This will make my up coming installation easier by just knowing what to expect.

[g725s]

I would not have just gone-for-it had it not been for your Electra build where you bent the down-tube and Spinningmagnets where he fitted the BBSHD inside the triangle of his Electra Lux Fat 7D. I thank both of you for the path you lead before me. I figured if you could just indent the tubing with your press jig, I could probably just hammer it. It took all of about 20 minutes to hammer it to fit. I recommend your way over my way, but I did not have that tool you have.

FYI, there is less than 1/16" wiggle room inside the triangle at this point. Sometime next week I'll be cutting the Bottom Bracket down in size. My plan also is to reinstall the chainguard. I think the 42t Bafang Alloy Chainring adapter is a good look for this bike, and with the chainguard in place it will really look good.

Do you have 3-4 rivet nuts you'd be willing to part with? I'm planning on mounting my Shark Pack inside the triangle on the down-tube.

http://electricbike.com/forum/forum/builds/ebike-building-directions/7325-bbshd-on-an-electra-cruiser?p=7342#post7342

and

http://electricbike.com/forum/forum/builds/ebike-building-directions/9435-electra-lux-fat-with-bbshd#post9435

[calfee20]

I had a hammer in my hand and while I was searching for swing angles and some sort of an anvil that wouldn't damage the tube I though of the press rig. I love the photo of the BBSHD fitted in the frame. I keep going back and looking at it........calfee

[g725s]

One thing about the BB is that I will need to use some "shim stock" to get the BBSHD to fit securely as it wobbles a bit. I had this same BBSHD in a Fuji Nevada with a 68mm Bottom Bracket and it fit super snug. So the BB on this bike has a slightly larger diameter. And after cutting it down in size, I'm going to have to assume it will wobble even a tad more.

[calfee20]

Mine was so tight I had to sand out the inside a little.

[calfee20]

I was just reading over at fat-bike about bike frames. http://fat-bike.com/2013/03/fat-bike-101-frame-types/ Then I looked at a photo you posted for me.



It looks like these Electra cruiser fat frames are offset. That should increase the possibilities of things I might want to do to my future bike.

[g725s]

I looked at that link you just posted then went out in the garage and looked at the Electra. I don't think it is offset like that. In the picture above I was trying also to show the chainline.

If I were to take a more centered picture both sides would look similar. I can't right now but will take a more centered picture later and post it here.

[calfee20]

If you are looking to keep your chain guard these may help. http://electricbike.com/forum/forum/...rd-if-you-must

[g725s]

If you are looking to keep your chain guard these may help. http://electricbike.com/forum/forum/...rd-if-you-must

Its not just protecting your pant from getting caught. To me it is a much better look.

Actually I'm thinking of using one of the bolts that hold on the controller (That one you can see just above where the wires come out , putting in an 1" longer one with a standoff) and I'm wondering about shallow drilling and tapping (with a bottom tap) into the controller or motor or motor fins somewhere. I'm thinking I could maybe/hopefully use the existing bracket, of course cutting and bending it.

[calfee20]

I drilled out the two rivets on the chain guard and I am still figuring the best way to attach it. I agree it does look better.

[g725s]

Yeah I'm not going to drill out the original bracket for starters. I really think I can use that one bolt that holds on the controller. I will cut and bend the original bracket. So once I do that I will have two mounting tabs coming off of the chainguard, one going to that bolt that holds on the controller, and that might just be enough. But I'll see what I can do with both tabs that will be coming off the chainguard once I cut it.

I also think I'll eventually be spraying the motor and chainring flat black to blend in better.

[calfee20]

I ran my wires under the BBSHD between the motor and bottom bracket. If you plan on doing this do it before completely bolting in the motor.

[g725s]

I'm not sure I'll have the same type of room that you've got there, after cutting down the Bottom Bracket and sliding in my 68mm BBSHD. Your using a 100mm BBSHD in a 68mm BB in that Electra you built there... http://electricbike.com/forum/forum/...=7346#post7346

I'm hoping to get down to 70-71mm.

[calfee20]

How wide are your rims? Easy outside measurement. A ruler is fine.

[g725s]

Using my Harbor Freight Cen-Tech calipers they are exact 81.86mm to the outside of the rim. Or 3.2228346 inches.

[calfee20]

Thanks. Wow 7 digit accuracy are we a pair or what.

[g725s]

I could put more digits on there if you need them ;-) LOL

[g725s]

I wonder if I'm voiding the warranty.....

If so it is too late now...







I only took the hose clamp off for a short time during the picture above. The hose-clamp was essential for getting a good all around cut. My suggestion for anyone that does this is go no more than 0.5mm deep ALL the way around initially. If you just start cutting you can cut into the hose-clamp (at one point early on I noticed I was cutting into the hoseclamp). So i went slowly ALL the way around, little by little.

I have this one side cut off and have checked the fit of the BBSHS. (then my camera battery died.)

But the fit of the BBSHD on this most important side is perfect chain alignment with the Bafang Alloy Chainring Adapter. I had calculated this with measurements I got from Calfee20 who precisely measured his Bafang Alloy for me. Thanks Calfee20. http://electricbike.com/forum/forum/...0630#post20630

[g725s]

Here are a couple of pictures where you can see the width of the stock 100mm Bottom Bracket. I'm cutting it down right to that weld on both sides to about 71mm, hopefully a tad less:

[g725s]

One thing I wish I'd have done is spent a little time putting some protective cardboard on the frame for all this work. I recommend that anyone doing this type of work gather up a little patience and protect the frame. I've only got a few very very minor nicks and scrapes but so much easier to protect ahead of time rather than having to come back later and touch-up.

if you decide to only protect with masking tape in some places double-up to triple-up at least.

[calfee20]

I just spent a considerable amount of time looking for Fat road tires, and there is not much choice.

Surley has a Black Floyd 26 x 3.8 http://surlybikes.com/parts/tires/black_floyd

Vee Tire Co has three
These two but one is an ugly whitewall http://veetireco.com/listings/?make=...view_type=list
This one is a giant slick http://veetireco.com/listings/fat-ti...e-fatty-slick/

Origin8 has two. The tread pattern you like. http://www.origin8.bike/product-desc...model_uid=8596
The tread pattern I like. http://www.origin8.bike/product-desc...odel_uid=12612

I think the factory tires will be the way to go. I wish there were more choices.................calfee

[g725s]

Actually I also prefer the tread you say that you like. But it is 4" wide and that would mess with the great chainline I have since I've cut the BB down in size. I was saying that the other one was the only 3.5" x26" that I could find after also spending considerable time online looking for 3.5" x 26" tires. Now that I've dialed in the chainline after cutting my BB down in size I need to keep the same tire width as the stock tire. I'm less than 1/8" from the tire in lowest gear, which is as good as you can get with the stock tire width.