Rebuilding the Boomerang Bike as an e-bike using Boost

[DCBassman]

Here's the BB:-
Merida Big Nine 40
What it needs:-
1) new tubes. The ones fitted are too big, just shoehorned in to get it up and running. Ready to fit.
2) New chain. The currently fitted one is pretty rusty, and the similar chain on the Scott too short, so... Ready to fit.
3) New bars. Despite having a very tall - uncut, in fact - steerer, I still need to be more upright. North Road bars. Ready to fit.
4) Boost electrification kit. Simplest fit and use, which also keeps the cost down. Ordered and paid, now just wait...
5) Lots of riding! I need to shed a few kilos before L to B, and I haven't exactly done a lot of work toward that goal. So the sooner this is built, the better.

I may get a second battery if funds permit, as getting from L to B on one charge will be a challenge, especially as the significant lumps are at the end.

 

[88robb]

Fix the bearings, fit the boost kit and get riding. North road bars will help. Second battery for the hills. Simple.

 

[DCBassman]

Started the process. New tubes and chain fitted. Zoom North Road bars and riser stem fitted. With the tall steerer, it's beginning to look like some sort of hybrid beach cruiser! Next step is to re-cable, current setup won't reach the bars. Parts in stock, so no issue. Boost kit should not be too far off now.
Am waiting for Boost to start shipping the new display unit. Meantime, I'll use an old iPhone 6S and the Boost app, with a small power bank added, in a water-resistant bar mount.

 

[DCBassman]

The Boost kit has arrived! Looks pretty damn good, too. Just waiting on some threadlock for new disc rotors, and it's build-an-ebike time!

 

[DCBassman]

Still not started this, but Easter Monday looking good weather-wise. 2nd battery incoming.

 

[DCBassman]

Ok, reasonable if windy day yesterday. The bike is recabled and now complete as a normal bike. I'd have finished the conversion too, but I'd forgotten one minor part - the spacer needed to fit a 9-speed cassette to an 11/12-speed hub! Also although sunhy, did I mention it was bloomin' windy, and cold. I'll post a pic of the bike as it is now, then some more of the actual conversion process.

 

[Punkawallah]

Tease :-)

 

[DCBassman]

The above post somehow didn't fly, so here it is, a day later than it should be. I got the necessary parts from Rockin' Bikes (by bus!) and started the actual conversion around 1pm, having first finished the easy job of making the Scott a 3x8 again - just the final gear cable and adjust.
It did not go well.
First, the minor but irritating fact that the tyre and this rim are a very tight fit. Ok, done.
Then, after struggling for 10 minutes, realised the only way to get the heavy wheel and its 'torque lugs' into the dropouts was to remove the bike from the workstand and upend it on the ground. Ok, done.
Then...the brake disc and caliper had to be fettled. This was the *really* teeth-grinding bit. Move the caliper to its outer limit. Still fouling somewhere. After much head-scrating, realised it was the fixed retaining washer on the rear caliper mount bolt. Spent an hour removing that. Refitted the bolt with plenty of Loctite and set about adjusting the brake again. Working. Grr...
Now to mount the battery interface. Guess what? On this frame, the dropped top tube means the battery has to go on the down tube, and there's not enough space left to get a bottle to the seat tube.
Make other plans for hydration...
Cabling was the promised cinch. Phew.
Dug out the iPhone 6S I'll be using as a controller, dropped in the battery, and powered it all up. Pedals turning, and whizz!
Finally...
So, after many frustrating hours, I have a working ebike. This morning will see me head out on it for a maiden voyage to Clearbrook and back. This gives me a general averagely hilly workout (there's no other type around here) plus one steep ramp at Leg O'Mutton. Also, the return leh is gently downhill from Horrabridge to the Gem Bridge, so I'll be able to give it some beans. And I WILL take photos, which will be prettier out there than the walkway I normally do my spannering on...

 

[DCBassman]

Tease :-)

Sorry, read the follow-up!

 

[Jameshow]

The above post somehow didn't fly, so here it is, a day later than it should be. I got the necessary parts from Rockin' Bikes (by bus!) and started the actual conversion around 1pm, having first finished the easy job of making the Scott a 3x8 again - just the final gear cable and adjust.
It did not go well.
First, the minor but irritating fact that the tyre and this rim are a very tight fit. Ok, done.
Then, after struggling for 10 minutes, realised the only way to get the heavy wheel and its 'torque lugs' into the dropouts was to remove the bike from the workstand and upend it on the ground. Ok, done.
Then...the brake disc and caliper had to be fettled. This was the *really* teeth-grinding bit. Move the caliper to its outer limit. Still fouling somewhere. After much head-scrating, realised it was the fixed retaining washer on the rear caliper mount bolt. Spent an hour removing that. Refitted the bolt with plenty of Loctite and set about adjusting the brake again. Working. Grr...
Now to mount the battery interface. Guess what? On this frame, the dropped top tube means the battery has to go on the down tube, and there's not enough space left to get a bottle to the seat tube.
Make other plans for hydration...
Cabling was the promised cinch. Phew.
Dug out the iPhone 6S I'll be using as a controller, dropped in the battery, and powered it all up. Pedals turning, and whizz!
Finally...
So, after many frustrating hours, I have a working ebike. This morning will see me head out on it for a maiden voyage to Clearbrook and back. This gives me a general averagely hilly workout (there's no other type around here) plus one steep ramp at Leg O'Mutton. Also, the return leh is gently downhill from Horrabridge to the Gem Bridge, so I'll be able to give it some beans. And I WILL take photos, which will be prettier out there than the walkway I normally do my spannering on...

Let's have some pics?!!

 

[DCBassman]

Let's have some pics?!!

I absolutely promise pics today!

 

[DCBassman]

Got the bike downstairs to the road and realised two things:
1) rear brake still binding.
2) I'm still wearing my carpet slippers...

Back up in the lift. Wheel off, a not insignificant task. Need removable cable ties. Remember there's a plastic part between the disc and the wheel/motor. Remove disc and spacer, refit without spacer. Refit wheel.
Check wheel spins freely before fitting brake? Check. Good. Refit caliper and jiggle it anout. Apply brake to centre it while nipping ip the bolts. Does wheel spin? Yes. Reapply brake. Release. Does wheel spin? Yes. Tighten bolts and put bike right way up.

Finally, ready to go. No, wait. Teas and pees first...
See ya later!

 

[DCBassman]

Ready to go, first attempt. Note fancy camo North Face slippers! Very good they are too!

Ready to go, and I actually did! Write-up in Your Ride Today.

 

[Punkawallah]

Hoorah!