Surly Pugsley 2.0 with BBSHD 100mm?

[Fhar]

Hi all,

Has anyone had success (or failure) with building the new, redesigned Surly Pugsley 2.0 with a BBSHD 100mm? I see this thread regarding a build with the older Pugsley, but it sounds like the updated version may have more intrusive chainstays, so wondering if the 100mm BBSHD will work. Ultimately thinking of using a Gates Carbon Drive system with Nuvinci N360 hub, if anyone has thoughts/experience on that.

[BigFatDummy]

Did you ever find your answer? Looking at building a Pugsly with the BSHD motor right now.

[Fhar]

Did you ever find your answer? Looking at building a Pugsly with the BSHD motor right now.

I didn't find an answer, but I gave it a go anyway. No way to make the Gates belt drive work, but I did get the 100mm BBSHD to work with a Nuvinci n360. It required a lot of spacers, though, and an offset crank on the non-drive side, as I recall, and the chainline ia a mess. If you're running singlespeed, I'd recommend chain tensioners to keep the chain from dropping constantly due to the bad chainline.

[BigFatDummy]

I got the Pugsley, but trying to work out if I should get the 100mm or 120mm motor. I've seen both builds but definitely worried about the chain line and I don't want the chain falling off like I've seen people saying...

[Dan816]

I decided to give it a go as well with the Pugsley 2.0 and 100mm BBSHD and I'm not liking it. I had to use 8mm of bb spacers in order to get the motor to clear the chainstays by a hair. The result of that many spacers is that you can't get the lock nut on the NDS to fully thread on. I've been told that the second lock not (the one that covers the first) is not necessary, but I'd still want at least one of the nuts to fully thread on. All that being said, I got the Lekkie 40t chainring with an alfine8 in the rear, and the chainline is perfect. Photos here: https://photos.app.goo.gl/3pUbyRRHxXhMBNnj7

Fhar, chainline issues aside, how did you get the motor mounted? Were you able to thread both lock nuts on the motor or just one? Fully threaded?

Thanks, Dan

[73Eldo]

Mine is a 2014 and didn't have those issues. Looks like 2018 was the re design and I think I found the problem on Surly's site:

The rear triangle was completely redesigned for larger tire clearance, in doing so we also made the bends a little more subtle. The frame was designed around our new 26 x 4.3” Edna and has clearance for them with racks and fenders. The new bike comes stock with a Race Face crank with the ring flipped and a 1x11 drivetrain. This allowed us to keep a 100mm bottom bracket shell and still fit a larger tire. There is still clearance for a double crank, but you may need to size down on tires to make sure there isn’t any chain rub in your lowest gears.

We also designed the frame to clear a 4.8” tire on an 80mm rim. Depending on the tire and rim combo, this will require using larger q-factor cranks (like those found on a Moonlander or ICT) and will require you to pull your wheel back halfway in the dropout (12.5mm). In order to run 4.8” tires on the front, a centered Moonlander fork is needed. This extra tire clearance allows you to experiment and set up your ideal off-road touring bike.