The Build

I knew I wanted to start with a lower voltage while still leaving the option to upgrade later, so I opted for the Cycle Analyst/Phaserunner combined with a Shengyi SX2 hub motor. I added in a torque sensing bottom bracket for that nice smooth pedal assist. Here’s where things get unusual: I designed and built a 36v battery using Samsung 18650 cells, assembled with my custom Cell-Lock system (pictured below). This allows me to add cells onto the existing battery if I ever want to, giving me the ability to increase to 48v or add more range in the future (although I might need a new BMS and enclosure!)

The full build wasn’t too daunting given the very thorough instructions supplied with all the components. I stared by lacing the hub motor into my existing rear wheel. This took a fair bit of fiddling with, but eventually I got everything true again and mounted it back on the bike. Next was removing the old bottom bracket, which had no interest whatsoever in coming off nicely, but after several hours of fighting with the pedal arms and axle I had everything free. Mounting the torque sensor was a breeze in comparison, after drilling a quick hole in the frame it just fit right in. The rest of the build consisted of mounting the screen and controls up on the handlebars, attaching the battery and controller to the cargo rack and wiring everything together.

I’ve had it out and about for a little while now and it’s great fun, especially the torque assist (well worth it for anyone considering). Next step for the build is adding back in the cargo space that I lost mounting the controller and battery pack, I’m thinking of adding a basket and saddle bags on top of the current battery. I also think adding disc brakes would be a good idea given the extra weight and power.