This is not an exhaustive list of the parts I am selecting, it is more to document my thoughts on the parts and why I selected them. I will put some of the costs involved too.
My first decision was regarding a donor bike. I was leaning to the new "fat" bikes. I like the look, and figured the wider tires could be useful off road and on snow and ice. I checked out the new Mongoose Mushaboom. Amazon offers it new for $659.99. It's a hard tail with a fixed front fork - no suspension other than the air inside the fat tires. As neat-looking as the fat bikes are, what I really wanted was good functionality with good parts. I would prefer a mountain bike with wider tires between 1.95 and 2.3 width. I ended up picking an older CCM Apex 6061 aluminum frame bike with most of the parts needing replacement. I would end up with the same effect as a new bike and with components that I pick for my needs.
First, let me go over the parts that repair the donor bike.
- bottom bracket - I ended up ordering a sealed 68x120 version ... sealed meaning that it is already lubricated and I don't have to worry about water, dust, dirt getting into the unit
- crankset - I chose a 1X version and will remove the 3 speed front derailer - reason for this is that this is an ebike meant to balance between pedaling and electric power, the rear gearset I chose is an 8-speed configuration, about all that will be needed
- pedals - I chose standard mountain bike non-slip pedals (the old ones were nearly seized and difficult to move)
- rear derailleur - I chose a mid-grade Shimano Altus 8-speed version
- gear shifter - I chose a mid-grade Shimano Altus 8-speed (right hand) version
- handle bar - not replacing yet
- seat - I have not chosen yet, I have a nearly new one now, just trying to rationalize which style before deciding
The total cost of the parts above is $318.58 including taxes and delivery charges. That is significantly less than buying a new bike, but I get pretty much the same effect (note, I have inspected the used frame carefully to ensure there are no cracks or other damage).
Let's go over the parts for the ebike portion of the build.
The first decision to make is on the conversion kit, that is the electric motor. A conversion kit usually includes all the parts needed to convert a regular bike into an ebike. That often also includes the battery. I have already decided to order the battery separately.
The conversion kit I chose is a dual power version. In Ontario, the law requires ebikes to be limited to 500w and a maximum of 32 kilometres per hour (kph). That is equivalent to US 20 mph. The speed is not well regulated at all. If you read advertisements on Kijiji, some of these ebikes will reach over 90 kph. I chose to do this the legal way and limit on road use to 500w and 32 kph. The dual power means this can also be used off-road with a potential of reaching 1.5 kw (1500 watts) and upwards of 45 kph. With the battery combination I chose, that can be extended further to 2.5 kw and likely 60 kph). I seriously doubt I will ever exceed 25 kph on-road or off-road. I am basically a chicken about this type of risk. Yet, I see some yahoos on our local roads regularly exceeding 50 kph (our local speed limit) and even travelling off road between the road, shoulder, ditches, and sidewalks. Where's the cops when you need them? Some of these yahoos are ebiking in a dangerous manner putting pedestrians at risk.
The version kit I chose is a 9 Continent C9 1500w kit with a 35A controller, pedal assist cadence sensor, throttle-style speed actuator, basic LCD, with a 26-inch wheel to match the frame size of the donor bike. This is designed for a 48v/52v battery system.
These kits typically sell for around $800 without the battery.
The battery is massive and one of the largest capacities available. The reason I wanted to keep the battery and conversion kit separate is that batteries can be dangerous. I wanted a battery from a Canadian company that had a full warranty. I also wanted the maximum size battery for this conversion kit, that could be transplanted to another kit if and when I wanted. This battery fits the need. There were batteries advertised on Kijiji that were the same capacity, and a lot less $$, but no warranty and no follow up names or phone numbers. Sorry, too much risk: and to the vendor that argued with me about this: I don't care about your 8 years of experience making batteries - I don't know you or of you, I don't know the quality you put into batteries - but if you don't have liability insurance and a warranty to back up your builds then I can't buy from you (regardless of the initial $$ savings). I'd rather have the protection.
Also of note, the Kijiji cheaper batteries did not include a mounting system, did not include key locks, did not include a power switch. They did include a mounting triangular bag, nothing else (and certainly no warm and fuzzy feeling).
After negotiating with the conversion kit vendor, I ended up with a combined cost of 1302.27 for the battery and conversion kit. Note, the battery was considerably more expensive than the kit. That is typical for an ebike, with some batteries selling for several thousands of dollars.
Overall, my build currently stands at $1620.85 ... that is roughly 1/3 the cost of a commercial version of this bike.