Custom DIY - Hand Grip Integrated PAS Switch - It's the "cat's meow"

[Tom@WashDC]

In my quest to improve my mtb riding experience, I've always wanted a grip integrated PAS selector switch so I would never need to adjust my grip, hand, or thumb while shifting PAS level on the fly. I wanted to use my index and middle fingers to move the PAS level up or down. Not a big deal if riding on the road or paved trails, but I find it to be very convenient when riding aggressive mtb style, off road. And it just makes more sense.

I'm sure there is a manufactured two button momentary switch that I could have modified out there. I almost modified an old push button Bafang PAS switch I had in my spare parts bin, but decided to build my own using some leftover parts, a used inner tube, and some momentary switches I purchased on Amazon for $9.00.



It works like a charm! Both the Bafang OEM switch and the grip switch work. Going to work on some improvements now.

It's the "cat's meow" of PAS switches.

 

[AHicks]

Nice idea. Getting pretty creative there Tom!

 

[Tom@WashDC]

Nice idea. Getting pretty creative there Tom!

Thanks Al!
I took out for a 30 mile test run. It beat all of my expectations. PAS shifting is lighting fast in coordination with my gear shifting. I can't believe this isn't a standard feature for e-bikes. I'm going to make some improvements to the switch. I'll keep ya posted.

 

[fooferdoggie]

Thanks Al!
I took out for a 30 mile test run. It beat all of my expectations. PAS shifting is lighting fast in coordination with my gear shifting. I can't believe this isn't a standard feature for e-bikes. I'm going to make some improvements to the switch. I'll keep ya posted.

it is on my bosch bike. it is a much better system then having to remove your hand from the bar.

 

[Deacon Blues]

Very nice, Tom.

 

[Tom@WashDC]

Very nice, Tom.

Thanks Deacon Blues! I'm lovin' it.

 

[onlineaddy]

First, let me commend you on your impressive ingenuity. I do have to wonder, however, why you change PAS levels so frequently that this mod becomes significant in your riding. Is your bike single speed? If not, wouldn't it make more sense to change gears than to change PAS levels for the varying terrains of an MTB ride?

 

[Rich W.]

First, let me commend you on your impressive ingenuity. I do have to wonder, however, why you change PAS levels so frequently that this mod becomes significant in your riding. Is your bike single speed? If not, wouldn't it make more sense to change gears than to change PAS levels for the varying terrains of an MTB ride?

I find it very convenient and helpful use both at the same time. Its basically an 11 speed manual transmission on the right and a three speed automatic on the left. For a quick burst on a short but steep hill or coming out of a wash for instance, all I have to do is bump up the PAS level then go back to Eco (or off if down hill) for normal riding. I use both together frequently and on my Spec Tero the PAS switch is within easy reach of my left thumb. I’m new at e-bike riding but I would have thought this was common. I can see how it wouldn’t make sense on a MUP, but after a couple hundred desert trail and cross country miles as my inaugural, my feeling is that its very helpful. Also it allows less road shifting as I can stay in the same gear as I climb a hill rather than losing momentum or risking a hard shift while climbing.

 

[Tom@WashDC]

First, let me commend you on your impressive ingenuity. I do have to wonder, however, why you change PAS levels so frequently that this mod becomes significant in your riding. Is your bike single speed? If not, wouldn't it make more sense to change gears than to change PAS levels for the varying terrains of an MTB ride?

Onlineaddy, thank you for the compliment!
So my first reason for designing this prototype is because I believe that the PAS switch should be seated underneath the fingers as they lay naturally on the grip. This is the most natural design, and makes the most sense from a bikers point of view. I notice the new TreK Domain SLR has the 3 level PAS switch located on the grip. Ideally this is the way it should be. So, that is what I wanted, a switch naturally positioned beneath my index and forefinger, but I couldn't find it anywhere, so I decided to make one. It's a game changer, for me.

My bike is a Luna Cycle Z-1, 12 Speed with a 160nm, torque sensing, Bafang Ultra mid-drive, drawing about 1,500 watts. I have 9 Levels of PAS adjustments. I choose 9 over 5 because it allows me to ride more efficiently and squeeze more juice from my battery as I can make finer incremental adjustments to my PAS levels as I ride based on the demand of the terrain.

That being prefaced, I could just leave it in a fixed PAS setting and then shift accordingly as the terrain demands, as you stated. On regular paved trails that is pretty much what I do. But I rarely ride paved trails in a casual way. As a default I usually ride in PAS 4-5, but while pulling a turn up into a 40-45 degree hill, I want to be able to bang it up to PAS 8-9 instantly, shift accordingly, maintain speed or accelerate up the hill, then bang it back down to PAS 3-4-5 when I reach the apogee, all the while shifting gears to maintain speed and cadence. This is my daily riding style. This new switch allows me to avoid the throttle completely, and get the most out of the torque sensing assist. Riding aggressively over rough terrain, with the standard thumb activated BAFANG PAS switch, I found myself sometimes missing the PAS button, having to fumble and look where my thumb was positioned, and always having to re-adjust my thumb position off the grip, then back onto the grip. With my new switch I can keep my thumb tightly wrapped around my grip where it needs to be. Keeping my thumb and the rest of my fingers clutched around the grip is very important.

I made this video last year, riding my 9 speed, DIY FAT bike, coupled with the 160nm Bafang BBSHD drawing 1,500 watts. Since I started riding my Luna Z-1, I've been riding considerably more aggressive than in the video. My new switch makes aggressive riding a more enjoyable experience, and allows me to quickly shift up and down the PAS levels without looking for, or losing by thumb position, conserve battery power, and avoid the throttle completely. It feels more natural, safer, and more fun! Do watch the video in HD with the screen expanded. I am on the trailing bike shooting the vid.

 

[fooferdoggie]

I even do that on our mid drive tandem. use the assist levers over gears on uphill climbs

 

[onlineaddy]

@Tom@WashDC To have the ability to mod your bike to the way you ride (instead of the other way around) is gold!