Umair Gaines
Electric bikes and kits are more popular in Europe than in North America, but they can be expensive. Until recently, if you wanted a mid-drive electric bike, you were limited to buying an underpowered and overpriced 250-watt Euro electric bike. However, several notable mid-drive kits have come onto the market, allowing those on a budget to build a powerful mid-drive electric conversion. This article will discuss the process of building a mid-drive electric bike, including the parts required, the installation process, and the benefits and drawbacks of mid-drive systems compared to hub motor kits.
Characteristics and Values Table for Building a Mid-Drive Electric Bike
| Characteristics | Values |
|---|---|
| Motor | 48V, 30A, 1,500W/2-HP, 48V Bafang BBS02, 250W, 750W |
| Motor Flex | Bad |
| Frame Construction | Sturdy |
| Installation | Complex, Easy |
| Kits | Common hub motor, Mid-drive, Front Hub Motor, GNG BB-drive, Bafang Front Hub |
| Cost | Expensive |
| Range | Shimano HG400-9, Microshift Advent 11-46T Hardened Steel cluster |
| Parts | 1/2-inch diameter (0.500″), 12mm diameter shaft (12mm is 0.472″), 36V-100V 6-FET, 36V-72V 12-FET |
| Country | Popular in Europe |
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Choosing a sturdy frame
Frame Material
The material of the frame plays a significant role in its sturdiness and overall performance. Here are some common materials to choose from:
- Aluminum: Aluminum frames are lightweight, affordable, and commonly used in the electric bike industry. They are easy to set up and provide good performance for casual cyclists. However, they may not offer the best shock absorption, especially on rough terrain.
- Steel: Steel frames are known for their strength, durability, and better shock absorption capabilities. They are a sturdy option for heavier riders or those who enjoy off-road adventures. While steel is heavier than aluminum, it provides a smoother ride and is easy to repair.
- Carbon Fiber: Carbon fiber frames offer an excellent strength-to-weight ratio, making them lightweight and strong. They provide rapid acceleration and an extended battery range. However, they are more expensive and may not be suitable for heavyweight cyclists as they have a higher chance of breaking.
- Titanium: Titanium frames are rare but offer rust protection and a smooth riding experience. They are lightweight, strong, and come with a high price tag.
Frame Design and Geometry
The design and geometry of the frame impact the bike's weight distribution, load capacity, shock absorption, and overall performance. A well-designed frame enhances durability and improves handling. Consider the type of terrain you will be riding on and choose a frame style that suits your needs. For example, if you plan to ride on trails, a mountain bike-style frame with a more upright position might be preferable.
Rider Characteristics
Your height, weight, and riding style will influence the frame choice. Many manufacturers provide size charts based on rider height to help you select the appropriate frame size. Ensure there is adequate clearance when straddling the top bar. Additionally, consider whether you prefer a step-through or traditional frame design, which affects the ease of getting on and off the bike.
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Selecting a motor
When selecting a motor for your mid-drive electric bike, there are several factors to consider. Firstly, determine your intended usage and personal preferences. If you plan to ride off-road, on hilly or challenging terrain, a mid-drive motor is often a better choice due to its power, efficiency, and adaptability. Mid-drive motors are centrally located near the bottom bracket or crank area, delivering power directly to the chain or belt and then to the rear wheel for propulsion. This centralized positioning provides a more natural riding experience, efficient power delivery, and better handling and control on rough terrain. They also tend to offer higher torque, making them suitable for climbing steep hills and riding on rough trails.
On the other hand, if you prioritize a low-maintenance, lightweight, and straightforward commuting option for city use, a hub motor might be more suitable. Hub motors are integrated into the front or rear wheel hub of the bicycle, resulting in a simple and discreet design. They are known for their low maintenance requirements as they have fewer moving parts compared to mid-drive motors. Additionally, hub motors are typically more affordable and easier to install due to their mass production, especially from Chinese manufacturers.
It's worth noting that mid-drive motors tend to be more expensive and complex. Their installation and maintenance can be more involved and costly compared to hub motors due to their complex design and close relationship with the chain and gears. The higher torque of mid-drive motors can also put more stress on the frame, potentially reducing its lifespan.
When selecting a motor, consider the trade-offs between performance, maintenance, and cost. If you prioritize power, torque, and off-road capabilities, a mid-drive motor is ideal. However, if you seek a low-maintenance, lightweight, and affordable option for urban commuting, a hub motor might be a better choice.
Additionally, when choosing a motor, consider the range you require for your rides. For shorter-range bikes, the Shimano HG400-9 is an excellent and affordable option, offering a range of tooth counts to choose from. For a wider range, the Microshift Advent 11-46T Hardened Steel cluster is a durable and cost-effective choice, providing a wide range of speeds for a mid-drive build.
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Conversion kits
Another vendor, Cycmotor, offers similar conversion kits, including the CYC Photon Mid-Drive Motor Kit, the CYC X1 Pro Gen 3 Mid-Drive Motor Kit, and the TSDZ2B OSF Upgrade Motor Kit. These kits vary in power and features, so it's important to research which one best suits your needs.
When choosing a conversion kit, it's important to consider the construction of your bike frame. The electric motor in a mid-drive setup can put a lot of strain on the frame, so a sturdy construction is necessary to prevent flexing or damage. Additionally, the type of motor and its placement can impact the efficiency of your e-bike. Common motors have three phases of electromagnetic coils, and controllers can be modified to increase the number of amps without overheating.
Lastly, when building your mid-drive electric bike, it's crucial to be mindful of common mistakes to ensure a trouble-free riding experience. Some essential components, like tightening bolts and tyre air pressure, are often overlooked, so attention to detail is crucial.
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Installation
Firstly, you must select a suitable motor. Common motors have three phases of electromagnetic coils, and controllers can be added to manage the amps without overheating. The motor should be mounted in-line with the wheel, and you will need to consider the diameter of the shaft and the tooth-counts on your drive sprockets. You can choose between a 1/2-inch or 12mm diameter shaft, with the smaller shaft providing more "meat" on the sprocket collar.
Next, you will need to select a drive system. For a powerful setup, consider a 48V x 30A system, which will provide 1500W/2-HP. You can also look at the GNG BB-drive, which is affordable but has some issues that can be fixed with parts upgrades. If you are looking for a super-powerful setup of over 2000 watts, a hub motor kit may be more reliable, as mid-drives have more moving parts and are less reliable.
When it comes to the bike itself, you will need a sturdy frame to handle the electric motor's pull on the chain. A typical mountain bike should be able to handle it, but a lightweight road bike may not be suitable. You will also need to consider the gears, as the motor will use them to stay in its efficient RPM range. This will give you more range per battery.
Finally, you will need to assemble and install all the components, which can be done by following the instructions provided with your chosen kit. Ensure all bolts are tightened and tires are inflated before testing your new mid-drive electric bike.
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Maintenance
Maintaining a mid-drive electric bike is similar to maintaining a conventional bike, but with a few extra considerations. Here are some key maintenance tips to keep your electric bike in good condition:
Regular Maintenance Schedule:
It is important to set up a regular maintenance schedule for your electric bike. This can be done either by yourself or by taking the bike to a professional bike shop. A basic tune-up includes truing the wheels, checking and adjusting the brakes, inspecting the condition of the brake pads, drivetrain, and chain, and ensuring proper tire inflation. It is recommended to have a yearly tune-up before the riding season or more frequently if you ride often.
Battery and Power Conservation:
Always top off the battery charge whenever possible, and remember to conserve power while riding. Riding an electric bike with a dead battery is challenging due to the added weight and resistance of the motor.
Flat Tire Repair:
Learning how to fix a flat tire is essential. For mid-drive electric bikes, the process is similar to that of a conventional bike. However, hub-drive motors are more complex and require knowledge of disconnecting and reconnecting electrical connections. Invest in replacement tires designed for e-bikes, which offer sturdy sidewalls, good traction, and puncture resistance.
Brake Inspection and Adjustment:
Regularly check and adjust your brakes to ensure your e-bike has adequate stopping power. Before each ride, look for any loose parts or excessive rotor and pad wear.
Chain Maintenance:
The chain is a vital component of the drivetrain system and requires regular maintenance. Clean, lubricate, and inspect the chain frequently. For a high-quality wax-based chain lube, apply it every 50 miles or when needed.
Spoke Tension:
Check and correct the spoke tension periodically. If you break a spoke, consider taking the bike to a shop to match and replace it properly.
Drivetrain Maintenance:
Keep the drivetrain clean and lubricated as needed. If your e-bike has a belt drive system, simply monitor belt wear and replace it according to the manufacturer's recommended schedule.
Owner's Manual and Service Levels:
Refer to your owner's manual for suggested service levels and maintenance cycles, which may be programmed into the bike's computer. The frequency of basic tune-ups will depend on how often and in what conditions you ride your e-bike.
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Frequently asked questions
There are several electric bike conversion kits available on the market. Some popular options include the Cytronex, Swytch, and Rubbee. If you're on a tighter budget, the Bafang Front Hub kit is a good option, although the installation process is more complex. The Bafang BBS02 is also a great choice for those seeking a quiet, powerful, and easy-to-install mid-drive kit.
It's important to select a sturdy frame that can withstand the torque and power of an electric motor. Additionally, consider the complexity of the build, as mid-drives tend to have more moving parts and can be less reliable than hub motor kits. Chains and sprockets may wear out faster on mid-drives, especially high-powered ones.
Mid-drive electric bikes offer several benefits. They tend to have a broader range of performance, as the motor can use the bike's gears to stay in its efficient RPM range, resulting in more range per battery. Mid-drives also perform better on steep hills and stairs, and flat tires are easier to change due to the lack of a hub motor.
