377: eBike Project - The Build

In this episode, follow an in-depth, step-by-step journey of transforming a surprisingly decent Ozark Trail mountain bike into the first Pedalshift e-bike (n=3 or 4 if you’re counting). This mega-pod takes you from the initial setup to final tweaks, including component replacements, brake and pedal adjustments, and install of a mid drive motor. I’m hardly a bike mechanic, so will things to go sideways at least once like my typical bike adventures? eBike Project - The Build Hey I got an ebike! Where did I end up? Decided on build over buy - more flexibility Decided on new over used - couldn’t find a good used one that wasn’t $$$ Went with a Bafang middrive motor and a 52v 20Ah frame mounted battery - smaller than Brian’s, but still pretty big. Watched a ton of YouTube videos and bought some tools! This took me several weeks because the bike lived at the cabin and I was back and forth a bit as I built it This was a journey… and the episode is a little long, but definitely brings you along tour journals style for how it went… 00:00 Introduction and Episode Overview 01:54 Choosing the Right Bike for the E-Bike Conversion 05:52 Initial Setup and Component Replacements 10:56 Challenges and Adjustments 18:05 Programming and Configuration 28:45 Battery Insights and Expectations 41:03 Assembly and Troubleshooting 48:11 Rear Brake Discovery 48:27 Chain Installation Challenges 48:30 Nighttime Reflections 49:27 Final Adjustments and Cable Management 50:51 Chain Sizing Tips 51:47 First Ride Impressions 52:32 Handlebar and Screen Setup 52:51 Rear Brake Issues 55:28 Pedal and Crank Problems 58:54 Cable and Sensor Installations 01:01:44 Tire Upgrade 01:04:14 Battery and Range Concerns 01:04:53 Shakedown Ride Plans 01:07:23 Final Preparations 01:16:47 Shakedown Ride Execution 01:25:48 E-Bike Confidence Boost 01:30:36 Closing Remarks and Future Plans