Converting a Bacchetta Giro ATT 20 to e-Assist

[Aushiker]

I have made some progress on my proposed conversion of the Bacchetta Giro 20 ATT to an electric assist recumbent. My primary use of the bike is a 42 km commute (each way) with around 250 metres of climb. During the summer the ride home is into a headwind which averages 20 to 30 km/h most days. I am able to setup a charging station at work.

My thinking is the following front hub build. I have gone through and pretty much discounted mid-drive and rear-hub options so back to a front wheel hub motor conversion.

I would value feedback on what I have proposed. Oh I am in Australia so we are legally limited to 250 w but happy to run at 350 w. I am also a complete novice at the e-bike stuff so have tended to go with what I hope is pretty much a quality plug and play conversion. I will be building the motor into a 20" front rim.

My proposed conversion is …

• Motor: Outrider Small Geared Front Hub, Fast RPM, Disk Compatible
• Controller: C3620-NC 20A Sensored/Sensorless Infineon Controller
• Throttle: T-HTwist Half Grip Twist Throttle, 2m Cable with 3-pin JST Connector
• PAS: PAS_12P 12 Pole Magnet Ring and Split Pedelec Sensor, works on left and right with CA3
• Torque Arm: TorqArm_V2 GRIN Front Torque Arm
• Cycle Analyst: CAS-DPS V3 V3 Direct Plug-In Cycle Analyst with speedometer and accessory cables
• Lights/Accessories Splitter: AndersonTap Anderson Powerpole Tap
• Brakes: HWBS Hidden Wire Brake Sensor
• Bacchetta Steel Front Fork and maybe a Bacchetta Recurve seat

My remaining issue is the battery and mounting it. I am more and more inclined to go with a rack mounting as I like the look of it as per this install (see photo). If I go this way I would like a black rack and battery case, so if anyone has any suggestions on the best options battery and rack wise that would be appreciated.



For the Battery I am thinking eZee 36v 14Ah 504w with Samsung cells (B3614LIM-EZ) combined with a eZee Double Decker for the rear Rack.

I also need a DC-DC converter. Is this what the Anderson Powerpole Tap is from eBikes.ca? I want to run my Busch & Muller front and rear lights off the battery if possible.

Finally is there anything I have missed? Cables for example?

Thanks
Andrew

 

[Admin]

Hey Andrew! This looks like an awesome setup. I wish I could validate your design and offer help with the power conversion stuff but I'm also a novice at ebike conversion... I touched up your post and visited the different links to learn more. I think the Powerpole Tap is designed to siphon electricity from the system to be used for lights and other accessories. Not sure about the converter question.

This seems like a great way to electrify a recumbent. A lot of the trike style bicycle riders use push trailers but they're more stable with three wheels. I've been thinking recently that you could electrify a Burley Trailer and have that push nearly any bike, maybe with a kit like the Leed 30k which can come in 20" wheel size. Then you could haul stuff as well as getting a boost

 

[Aushiker]

Well I still haven't made a final decision on the conversion of my Bacchetta Giro 20 ATT recumbent to an electric assist recumbent. Well that was the plan till a spot thinking on the chair in the shed this afternoon and I may go with a conversion of my LoGo P-38. If I decide later I can easily switch over the kit to the Giro and spend the extra dollars to add a steel front fork and a Recuve seat if desired.



I have picked up on rscamp's suggestions at BentRider and have gone a step further based on Paul at EM3EV advice and will probably get a 48V (50V) 14.25 battery.

Anyway the latest proposed conversion is as follows ... just need to make the final decision on the actual kit. I really need to pull the trigger on this

• MAC 350W 14T Front Kit OR a MAC 500W 10T with a 9 fet controller
• EMV3V 50V 14.35 Ah Samsung Battery Pack
• Thumb throttle
• Pedal Assist Sensor that works with V3 Cycle Analysis speed sensor
• TorqArm_V2 GRIN Front Torque Arm x 2
• CAS-DPS V3 V3 Direct Plug-In Cycle Analyst with speedometer and accessory cables
• HWBS Hidden Wire Brake Sensor x 2
• Grin Tech 6V 12 Watt Output Rugged DC-DC Converter, for 24V- 48V Batteries

Battery mounting is probably via a battery bag hanging off the left "pannier rack" on the LoGo P-38 or if I go with the Bacchetta via a rear rack.

Would value any input into this build. Paul at EM3EV seems to favour the MAC 500W kit over the MAC 350W kit and does point out I can step it back with the Cycle Analyst if I so desire. I guess it gives me more flexibility if I find I need it dealing with the headwinds.

Thanks
Andrew

 

[Admin]

I'm excited for you Andrew! Sounds like a great setup you're going for (and very unique). I don't have much to add here but I think you're right on with the rear rack bag if possible. Maybe you could put the battery in there and still use side panniers for other stuff? I think the top-style bag would just swing around less and be easier on a battery and it would keep the bike weight more balanced from side to side... though a bit higher up

 

[Aushiker]

Thanks Court but I sometimes wonder if I should have done what you prefer and buy an off-the-shelf e-bike

Andrew

 

[Admin]

Thanks Court but I sometimes wonder if I should have done what you prefer and buy an off-the-shelf e-bike

Andrew

Well, it's exciting to hear about your project and sort of experience the process vicariously. I'm sure you'll end up with something great (and unique). There aren't many recumbent ebikes but I am excited about the evolution of ebike pushers, electrified trailers and stuff. I'd like to see a Leed or Clean Republic kit mounted on a Burley - this is what Ridekick was working on before they paused for the year.

 

[Aushiker]

Well the build has started; well to be more precise the parts and accessories have been ordered and the first few bits arrived today. Really impressed with the service from JensonUSA with four days delivery from the good ol' USA to my door here in Western Australia.

In the box was ...



K-Edge Gopro Pro Handlebar Mount for mounting my GoPro up front. A requirement for riding around here. Also makes it easy for me to swap my camera between my two main bikes.



A pair of SKS Slidecage Bottle Cages. These allow for the side mounting of the cage which makes accessing the water bottle much easier on the recumbent.



Ergon GP1 Performance Comfort Grips. These are so comfortable, both my recumbents have got them now and I will add them to my mountain bike in the future. Cannot recommend them enough.

Regards
Andrew

 

[Admin]

Nice, that's a cool looking GoPro mount. I've been trying a bunch (to get smooth video during test rides) and have struggled to find designs that are firm but also fast to mount/unmount.

 

[Aushiker]

Nice, that's a cool looking GoPro mount. I've been trying a bunch (to get smooth video during test rides) and have struggled to find designs that are firm but also fast to mount/unmount.

They are really solid and I have had no issues with them from a stability point of view and that is even though they require a 31.8 mm bar and I have narrow bars and hence have to pack them out. This is a taste of the stability using a E-Edge mount with the GoPro Hero 3 mounted on my LoGo P-38 handlebars

Andrew

 

[Admin]

Nice, I like how your feet kind of pop in and out of the frame

 

[Aushiker]

Nice, I like how your feet kind of pop in and out of the frame

BTW a truck rolled over this morning right near the start of this video...



Andrew

 

[Aushiker]

I forgot to mention before but I have coupon code for JensonUSA for 15% off one full priced item. It expires in 30 days. Happy to pass on to the first person to drop me a PM (?) requesting the code. Hopefully someone can benefit from it.

Andrew

 

[Admin]

Wow! I'm glad you weren't riding near the truck when that happened... Thanks for the coupon code offer! Feel free to post it in the Deals section of the site, maybe someone will happen across it if you link to the site and talk about the different bikes they sell (and what you bought).

 

[Aushiker]

Progress is slowly occurring. I now have the Bafang BBS01 36v 350W motor and all the other bits and pieces I wanted for the conversion (e.g., rack) bar the battery. The battery was coming via FedEx in a separate parcel and FedEx flew it into Perth where I am and then promptly sent it over to the other-side of the country. Hopefully it will turn up next week.



More photos at Google+ Photos if interested.

Regards,
Andrew

 

[JoePah]

? Andrew what happened to the MAC? Just wonder what made you decide to change to a mid drive

 

[Aushiker]

? Andrew what happened to the MAC? Just wonder what made you decide to change to a mid drive

The feedback around the place was less than supportive of a front hub motor and then I did consider a rear hub motor but the issues with punctures (doing my commute distances this is an issue), lower quality gear components, possible fit issues) and the idea/look of the Bafang BBS01 that appealed so decided to be adventurous and goes this way.

I am sure a hub motor would have been a reasonable option as well.

Andrew

 

[Aushiker]

Its done, well my Bacchetta Giro 20 ATT with Bafang BBS01 e-Assist (pedelec) had its maiden ride today. Nothing to long, just 30 odd minutes as I am currently restricted to 30 minute rides plus there a still a few niggles to sort out in terms of fine tuning the rider setup and front brakes as well as a couple of bigger issues to resolve.



The main issue to resolve in terms of the conversion is the rear rack. The Topeak MTX Explorer Tubular Rack w/disc rack is simply to tall for this bike so will have to look at other options. Ideally whatever rack I use will take a European rear light but at least it must have a plate on the top to allow mounting of the battery. The search begins.

I am also not happy with the wiring so will look at getting some wire mesh guard to tidy up the wiring once I have the Busch & Muller e-bike light to go on the front in place of the dynamo powered light there now.

Regards
Andrew

 

[James]

Good looking bike Andrew! I pass a fellow almost everyday (going the opposite direction) with a recumbent bike. He and I actually stopped the other day and swapped ebike/commuting stories. Good times!

 

[Aushiker]

At long last the conversion is complete. I really have nothing more to do to the bike other than building a programming cable to allow me to program the Bafang BBS01 and to maybe add a watt meter. I haven't been able to ride it much due to injuries, holidays and now illness :roll: but what riding I have done does suggest some tweaking of the motor would be worth if. Overall I am happy with the conversion and the ride experience. I have fully documented the build on my blog here for those interested.

Andrew