Disclaimer
Embarking on this project comes with inherent risks, ones I personally avoided for nearly a decade. The primary concern arises from the frequent removal and reinstallation of the wheel. This repeated process increases the chance of improperly seating the wheel, which can lead to dangerous situations. While meticulous care during each installation aims to mitigate this risk, a more permanent solution is always preferable. If secure parking or indoor storage for your commuter bike is an option, it eliminates these complications, offering a more reliable and safer approach. Deviating from manufacturer recommendations should only be considered if you are comfortable with potential compromises and are prepared to actively manage the associated safety risks.
That being said, this setup has proven effective for my needs, and I hope it can inspire others facing similar limitations. However, it’s crucial to remember: never exceed a speed you’re not prepared to crash at, always wear a helmet, and practice defensive riding. Especially in environments where vehicles are prevalent, prioritizing safety is paramount.
Let’s move forward!
Powering Your Ride with an EGO Battery
While I haven’t explored compatibility with other tool battery platforms like Greenworks or Stihl, it’s worth investigating if you’re already invested in a different system. It might be possible to power your hub motor with an alternative tool battery.
Using tool batteries inherently involves calculated risks. Batteries specifically designed for e-bike systems are generally safer and more reliable for this application. Tool batteries also typically offer lower capacity compared to dedicated e-bike batteries, directly impacting your range. For instance, EGO’s highest capacity battery is 10Ah, which is considered entry-level for e-bike batteries, with many going significantly higher. This means you should expect a reduced range compared to standard e-bike battery solutions when using an EGO battery.
Choosing the Right Hub Kit: Front Wheel Electric Hub
My journey led me to a front-wheel electric hub kit, a fantastic Christmas gift from my children in 2022 (a compelling reason to have kids!). This particular kit has served me well:
https://www.amazon.com/JauoPay-Electric-Bicycle-Conversion-28mile/dp/B08TMC2F9C
For future reference, in case the link becomes unavailable, here’s the product description from the Amazon listing, preserving its almost-perfect translation:
“About this item
[HIGH SPEED] – 48V 1000W Powerful brushless gearless front hub motor can be reach up to 28mile/h (45km/h) speed, and restricted to 750W and 24mile/h speed by default as a road-legal pedal bike conversion kit. Aluminium Alloy rim with spokes. Dropout: Front 100mm/Rear 135mm.
[Dual Mode Controller] – Motor works under Hall effect and non-Hall effect, extend life for electric bicycle.( If the components break down, controller will switch into non-hall effect mode, the motor will still be working.)
[RIDE EASILY] – 8 point high effective Pedal Assist System (PAS) can activate the hub motor with the pedal driving, allows you to combine electric power and your own effort with a nice and easy riding way.
[Durable Construction] – Double Wall Aluminum Alloy Frame provide high durability as a bicycle wheel, 12 G × 2.6 mm High Carbon Steel Spoke provides nice stability for the rides, the magnificent construction can support a heavy weight up to 220 Lbs.
[ALL Necessary Components Included] – 1000W Hub Motor Wheel, intelligent controller, twist throttle, brake levers, 8 point pedal assist system, cable ties and user manual. (Battery and tire are not included.)
Key Features:
- 48 V 1000 W super power Brushless Gearless Hub Motor
- Restricted to 750 W and 24 mph by default as a road-legal kit.
- Aluminum Alloy Double Wall Rim, with 12 G × 2.6 mm Carbon Steel Spoke.
- Rare-earth metal magnet are used in the motor to efficiently produce large power.
- Brake Levers cut off the power supply to the motor safely.
- 8 Point Crank speed sensor for pedal assist, can allow you to works with all pedals, including Speedplay and Eggbeaters.
- Dual Mode Controller, Motor works under Hall effect and non-Hall effect, extend life for electric bicycle. (If the components break down, controller will switch into non-hall effect mode, the motor will still be working.)
The 1000 W system requires a 48 Volt battery with a nominal capacity not less than 11.6 AH or 52 Volt battery with a nominal capacity not less than 13 AH (If you chasing a higher speed)”
Streamlining the Conversion: Modifications for Practicality
To simplify the process of installing and uninstalling the e-bike components, I made a few key adjustments focusing on minimizing wire handling and improving usability.
Throttle Adjustment:
The original throttle mounting bolt required an Allen wrench, which was inconvenient for frequent adjustments. I replaced it with a thumbscrew, enabling hand-tightening and loosening. Due to limited space on the right handlebar, occupied by my bike’s seven-speed shifter, the throttle initially felt awkward. Relocating it to the left handlebar provided a better fit. While this resulted in an upside-down display and a learning curve for left-hand throttle control, it ultimately optimized handlebar space and functionality. To maintain a comfortable riding posture and hand position, I extended the right handlebar using PVC. This modification allowed me to shift and pedal naturally while keeping the throttle on the right side, where it intuitively belongs for many riders.
Brake System Considerations:
I opted to skip installing the included brake levers. These levers appeared to function solely as power cut-offs to the hub motor. However, the throttle already provides instant power control. Given my intended lower speed usage, my bike’s existing standard brakes – a rear disc brake and a front V-brake – offer sufficient stopping power. For riders prioritizing higher speeds or more demanding terrains, integrating the provided brake levers might be a worthwhile safety enhancement.
Pedal Assist System (PAS) – To Include or Not?
Based on user reviews, particularly the one cited below, I decided against utilizing the Pedal Assist System (PAS) included in this kit. While adjustable PAS systems exist, the PAS on this budget-friendly kit seemed to be set to maximum assist permanently. According to reviews, it delivers near-full power almost immediately upon pedaling. This abrupt surge of power felt potentially unsafe and overly assertive for my riding style.
I found the twist throttle to offer remarkably smooth and progressive acceleration. It allows for nuanced control, providing just a slight boost or full power as needed. I typically engage the throttle only when tackling uphill sections and when already in motion. While I do pedal lightly while using the throttle – partly out of habit and partly to facilitate a smoother transition back to unpowered riding after reaching the crest of a hill – I concluded that the PAS in this system would likely feel less responsive and more challenging to manage.
PAS Review Snippet: “The PAS is not adjustable so when you start to pedal, it seems to want to go to near full throttle, too fast for what I want. When using the twist throttle (which is quite smooth and comfortable), if I start to pedal, it immediately wants to go up to 25+ mph, too fast. If I disable PAS, it works fine as a motorcycle with pedals. It’s very strong, excellent on hills and quite easy to get accustomed to, but I built it for my wife who is not interested in winning acceleration races, so I guess I’ll just disable PAS altogether.”
Conclusion
Converting your bicycle to an e-bike using an EGO battery and a front hub motor kit presents a viable DIY solution, especially for those already invested in the EGO battery ecosystem. While it requires careful consideration of safety aspects, particularly regarding wheel installation and battery compatibility, the modifications outlined can enhance usability and personalize the riding experience. Prioritizing safety, understanding the limitations of tool batteries, and carefully choosing components are crucial for a successful and enjoyable e-bike conversion. Remember to always ride responsibly and within your comfort level.
