After much deliberation, I have decide to do an E-Bike conversion on my 2009 Surly Long Haul Trucker.
I have put over 20,000 miles on the LHT in the past many years. Lots of touring, commuting and recreation. I really enjoyed that bike. Since getting a Felt E-Bike and getting older, the LHT just didn't get used as much. It was set up great, with White Industry Hubs in custom wheels. A real nice bike.
The Felt E-Bike is also nice but the Shimano Steps system (6000 series) is no longer made or supported. The Felt Bike frame motor mount will not accept the new Shimano Steps Motor systems. And the battery options for Shimano is extremely limited. The batteries and motor controller are proprietary. So while the Felt is still nice, a e-bike conversion of the LHT for Touring seems like a interesting and economical project.
Achieve a bit more power than the Felt Steps 6000 (250 watt) system for heavier load.
Achieve a little more increased sustainable speed for more daily mileage.
Achieve a throttle option if the situation is needed.
Achieve optional battery choices for given situations. Multiple batteries would allow adjusting the battery load for the needed distance.
First Concern Braking: Disc brakes would be a more 'sure footed' braking option. But the 2009 LHT has Rim Brakes. With recent new wheels/rims, and KoolStop - KS-MTTDL brakes, I think that the braking should be fine for a Touring Bike that travels on paved roads and maintained Rail Trails. The fact that the rim brakes are mechanical and the brake pads are very easy to inspect is a maintenance and safety plus.
Second Concern motor placement: I recently build the LHT wheels using very nice and expensive White Industry M15 hubs. It would seem pragmatic to use them. And now that I am very familiar with Mid-Drive Systems, a Mid-Drive motor instead of a hub motor seems to be the practical option.
Third Concern change of shifting. I considered a Rohloff SpeedHub but decided against it. They are very expensive and with the White Industry M15 hubs as discussed before, I think the pragmatic approach is stay with the wheels (front and rear) as built with the Shimano XT derailleur/gear system. (although the thought of a Gate Belt & Rohloff Hub is very intriguing, it is beyond the scope of this project)
Forth Concern shifting and braking levers. The current LHT setup is with WoodChipper handlebars with bar end shifters. This is a good time to put a Jones SG 2.5 Aluminum Loop H-Bar on the LHT. I have that Jones bar on my Felt and it works great for my purpose. This would require changing shifter(s) to use with the existing derailleur.
A mid-drive motor would eliminate the need for a front chain ring derailleur/shifter but I will obtain the pair for the conversion and use until the motor kit is obtained.
SHIMANO Altus SL-M2010-9R 9-Speed Right Rapidfire Plus Shifter $22.49
We will see if I can temporarily adapt the dropbar braking levers to the Jones Bar until the Motor kit with Brake Levers is obtained.
- SHIMANO Altus SL-M2010-9R 9-Speed Right Rapidfire Plus Shifter $22.49
- Jones H-Bar® 710 SG 2.5 Loop Aluminum & Black Jones Kraton H-Grips $100
Stay tuned for the conversion step postings as they happen.
(The Long Haul Trucker)
The Salsa Wood chipper Handlebars have been removed. It has been determined that the existing brake levers will not be installed even temporarily on the Jones 2.5 Loop H-Bar when it arrives.
The Jones H-Bars arrive and the installation begins:
The Jones bar is an easy install using the existing stem. It will take a bit of adjustment to get the level just right. The rear shifter is installed and it functions perfectly. Still awaiting new brake levers but I put on one of the great Jones Bar grips. I believe I will be able to but on the brake lever without having the remove the grips.
I am anxious to ride the new set up prior to proceeding to the actual E-Bike motor step. I want to confirm that the bike is dialed in and will be suitable for the E-Bike conversion.
The existing brake levers would not work, so inexpensive "Chooee Bicycle Brake Lever,Mountain Bike Handlebar Brake Lever for MTB, Black" were purchased and installed with new wiring. The front derailleur was removed making the Bike a 1x9. The bike will now be tested for a short time to confirm that it is working properly and the fit is dialed it before the e-bike conversion continues.
Select Electric Motor
The bottom bracket removal
|Tools and parts|
from my experience removing a bottom bracket
that had not been replaced for about 5 years
- I found it easier to have the bicycle upside down on the floor for this step. Having the bicycle in the repair stand created issues when additional force was needed removing the crank arms and bottom bracket.
- Use a pedal wrench to remove the Pedals.
Right pedals loosen by turning counter-clockwise,
Left pedals loosen clockwise.
- The crank bolts use the normal un-tighten counter clockwise pattern for both sides of bike.
- The Crank Puller Tool crank inserts into the crank with the normal tighten clockwise pattern into crank for both sides of bike.
- The Crank Puller Tool's removal bolt tightens (thus pulls/removes) the crank arm with the normal tighten clockwise pattern into crank for both sides of bike.
- Use a "cheater" extender on the wrench for leverage help with removal of the crank arms.
- After the crank arms are removed use the bottom bracket tool to remover the bottom bracket. Each side unscrews.
The Non-Drive side is removed using traditional Counter-clockwise pattern.
The Drive Side is removed using the Clockwise pattern.
I found it easier to remove the bottom bracket by standing on the opposite side of the bicycle and securely pulling the socket tool towards me, holding the socket in place, as I pushed down on the extended wrench handle to unscrew the bottom bracket from the frame.
- The entire process took about 1 hour going slowly and cleaning the removed parts.
The motor kit arrives
The Installation wasn't too difficult.
I spent a little time getting the cable wires arranged. I used a split cable wrapping product to route the cables. The finished product looks like this:
There is room for two of these batteries sitting side by side on the rack. Plenty of room for Panniers.
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