377: eBike Project - The Build

377: eBike Project - The Build

Author: Tim Mooney September 19, 2024 Duration: 1:34:31

In this episode, follow an in-depth, step-by-step journey of transforming a surprisingly decent Ozark Trail mountain bike into the first Pedalshift e-bike (n=3 or 4 if you're counting). This mega-pod takes you from the initial setup to final tweaks, including component replacements, brake and pedal adjustments, and install of a mid drive motor. I'm hardly a bike mechanic, so will things to go sideways at least once like my typical bike adventures?

eBike Project - The Build

  • Hey I got an ebike! Where did I end up?
  • Decided on build over buy - more flexibility
  • Decided on new over used - couldn't find a good used one that wasn't $$$
  • Went with a Bafang middrive motor and a 52v 20Ah frame mounted battery - smaller than Brian's, but still pretty big.
  • Watched a ton of YouTube videos and bought some tools!
  • This took me several weeks because the bike lived at the cabin and I was back and forth a bit as I built it
  • This was a journey… and the episode is a little long, but definitely brings you along tour journals style for how it went…

00:00 Introduction and Episode Overview

01:54 Choosing the Right Bike for the E-Bike Conversion

05:52 Initial Setup and Component Replacements

10:56 Challenges and Adjustments

18:05 Programming and Configuration

28:45 Battery Insights and Expectations

41:03 Assembly and Troubleshooting

48:11 Rear Brake Discovery

48:27 Chain Installation Challenges

48:30 Nighttime Reflections

49:27 Final Adjustments and Cable Management

50:51 Chain Sizing Tips

51:47 First Ride Impressions

52:32 Handlebar and Screen Setup

52:51 Rear Brake Issues

55:28 Pedal and Crank Problems

58:54 Cable and Sensor Installations

01:01:44 Tire Upgrade

01:04:14 Battery and Range Concerns

01:04:53 Shakedown Ride Plans

01:07:23 Final Preparations

01:16:47 Shakedown Ride Execution

01:25:48 E-Bike Confidence Boost

01:30:36 Closing Remarks and Future Plans


There’s a particular kind of freedom that comes from traveling by bicycle, where the journey itself becomes the destination. The Pedalshift Project: Bicycle Travel Adventures, hosted by Tim Mooney, delves into that experience through a mix of personal stories, practical advice, and wide-ranging conversations. Rather than just a how-to guide, this podcast feels like sitting down with a knowledgeable friend after a long day on the road. You’ll hear firsthand accounts from fellow bike tourists, each with their own unique tales from the pavement and gravel, alongside Tim’s own reflections and experiments in bicycle touring. The discussions naturally cover the logistical tips and tricks that make trips smoother, but they also explore the cultural and educational aspects of moving through the world at a human pace. It’s about more than gear and routes; it’s about the connections made and the perspectives gained when you embrace a slower, more engaged form of travel. This audio companion to Pedalshift.net aims to demystify bicycle adventure, making it feel accessible and deeply rewarding. By sharing these stories and ideas, the hope is to inspire your own two-wheeled explorations, proving that a bicycle can indeed shrink the world in the most wonderful way. Tune in for a thoughtful, grounded take on seeing the world from the saddle.
Author: Language: English Episodes: 100

The Pedalshift Project: Bicycle Travel Adventures
Podcast Episodes
Best of Pedalshift 290: Beginner Mistakes [not-audio_url] [/not-audio_url]

Duration: 25:28
I used to do a beginners series on the show (and hope to do another again) but never did a whole show on "don't make the same mistake I did." So, on this episode… mistakes to avoid as a beginner! Originally podcast July…
395: Florida Coast Part 2 [not-audio_url] [/not-audio_url]

Duration: 51:11
There are few rules in bicycle adventures, but I am a firm believer in the one that says you do not taunt the bike touring gods. Day 1 was a breeze, I said! The bike gods respond with a breeze of their own. Would their w…
394: Florida Coast Part 1 [not-audio_url] [/not-audio_url]

Duration: 1:27:44
The first day of the Florida Coast adventure starts from the cooler air of Jacksonville, carrying me south through a series of beach towns on the way to a state park outside of St. Augustine with two entrances… the short…
393: Florida Coast Preview [not-audio_url] [/not-audio_url]

Duration: 19:28
My annual tradition of a winter ride in the sunshine state continues! Unlike past years, I'm shaking things up with the start and focusing on a coastal ride along the East Coast Greenway before turning inland. But the Fl…
Best of Pedalshift 292: Touring Bike Essentials [not-audio_url] [/not-audio_url]

Duration: 35:10
I ride three different bikes for touring, and each one has plusses and minuses depending on what kind of ride I'm looking for. But if you're new to bike touring or looking for another bike, what should you be thinking ab…
392: eBike Range Test Takeaways [not-audio_url] [/not-audio_url]

Duration: 21:46
So I successfully rode 75 miles on a single charge of my eBike battery (with a little bit of a top off!). What did I learn from the adventure and what does it mean for future trips with my ebike? eBike Range Test Takeawa…
391: eBike Range Test Part 1 [not-audio_url] [/not-audio_url]

Duration: 1:22:52
On this episode we ride from my cabin to Cumberland, MD on the C&O towpath to see if we can squeeze 75 miles out of my eBike battery! With only one real opportunity to top off, this is a real test with fairly unfun conse…
390: eBike Range Test Preview [not-audio_url] [/not-audio_url]

Duration: 15:26
On this episode we turn the page back to last fall when I did a secret mini tour with a big purpose… to test the range of my eBike battery on the C&O trail! Can I stretch one full charge enough to get a full day's ride i…
389: 2025 Bicycling Goals [not-audio_url] [/not-audio_url]

Duration: 11:37
On this edition of the pod, we kick off 2025 with the intent to make it a year of celebration in a time of loss for me. But celebration is more fun, so let's do that. 2014's trip was a shout out to my grandmother and 202…
Best of Pedalshift 270: Winter Fitness and Bike Maintenance [not-audio_url] [/not-audio_url]

Duration: 27:34
With a bunch of snow and ice on the ground where I'm at, it's a good time to focus on things that will help bike tours coming after the thaw. On this episode, an update on my winter fitness goals, what I'm doing to keep…