Two Year Bicycle Review

It's two years since I recommenced cycling after a 40 year gap.  This return to cycling occurred as a consequence of my feet giving me grief when walking.  Pre-diabetic was the medical diagnose.  I needed to lose weight and see a podiatrist for orthotics.  Around this time I'd started to become bored walking the same daily local routes.  I thought cycling would have less impact loading on my feet and extend my travelling allowing me to view more locations.

I didn't want to spend much on a bike and clothing.  Eventually I selected a Merida Crossway 20 from a local bicycle shop which happened to be discounted.  The clothing consisted of an $8 Hi-Viz work shirt.  After a couple of rides the shirt was followed by a pair of cycling shorts and riding gloves.  My helmet was the cheapest I could find.  After being hit in the face by a large bug (fortunately it missed my eye) I bought a pair of $7 tinted safety glasses from the local hardware store.  On my feet I wear trainers and cotton socks.

The bike had front and rear derailleurs which provided 24 gears.   

It didn't take me long to realise a budget bike consists of budget components.  There was nothing particularly wrong with the bike, but I did struggle with two things.  The handlebars we so low I was always bent over.  My bad back made that clearly known.  The second issue was the derailleurs.  They always seemed to be moving out of alignment.

Knowing nothing about modern bike construction I initially attempted to raise the handlebars by loosening the top bolt and lifting them.  Modern bike aren't built that way!  My solution was to buy a stem extension from Aliexpress.  The longest one I could find!

This took the strain off my back as I could now ride in a more upright position.

After some research I decided to replace the derailleurs with an internally geared hub (IGH).  I narrowed my choice to either a Rohloff or Shimano Alfine.  The Rohloff is the better hub, but it's very expensive.  The Alfine was a third of the price.  Having decided on the Alfine I wasn't prepared to pay the Australian price, eventually managing to purchase one from Germany. 

I took it to a specialist wheel maker in Perth and had him fit it.

The removal of the derailleurs meant the chain no longer needs to flex horizontally.  The cog on the Alfine is in a straight line with the main ring gear.  This became important.

I wanted to keep riding the bike whilst the Alfine hub was being fitted so I asked the wheel maker to fit it to a new rim and spokes.  This proved to be another fortuitous decision as he suggested a stronger rim and spokes for the heavier Alfine Hub.  The subsequently meant I could tow a trailer or carry pannier bags 

The original tyres and tubes proved to be very thin and I quickly started to incur punctures from tiny thorns scattered around the local area.  That resulted in two more decisions.  The need for a puncture repair and toolkit carried in a small bag under the seat.

And a bike pump.  This is my third pump.  The previous two from Aliexpress fell apart.

I also replaced the original tyres and tubes.  No punctures since.

My cycling was taking me further afield and whilst my brain was enjoying the variety in scenery whilst my body was objecting to the more strenuous parts of the ride.

I started researching e-bikes and quickly realised purchasing a proprietary e-bike had two major disadvantages.  The first was cost.  They are very expensive!  The second was you become locked into the manufacturers "system".  Particularly the battery.  Each manufacturer appears to have their own battery shape.  I didn't want to buy an expensive e-bike only to discover in 5-7 years they no longer stock that battery.

My plan was to convert the Merida to an e-bike by fitting an electric motor and I opted for the most common street legal version.  A Bafang 36V 250W BBS01.  I waited for the Chinese 11-11 sales where I was able to buy the Bafang kit at a very discounted price 

I also bought the largest 36V battery could find at that time.  A 19.2Ah. I

The Bafang kit came with cranks, a main gear ring, speed sensor, LCD Display, throttle control, brake sensors and gear sensor.  The seller included a front headlight powered by the battery as a "gift".

I modified the existing brake levers to accept the Bafang brake sensors and started riding my e-bike.  Hills were no longer a major obstacle.  My fitness also improved as a gradually weaned myself off battery power.

My cycling range started to increase which made me think about improving the efficiency of the bike.  Removing the derailleurs and fitting the Alfine IGH allowed a straight chain whilst the Bafang provided more power.  I replaced the original chain with a stronger single speed chain (which didn't need to flex).  I also replaced the Bafang chain ring with a blue alloy version from Aliexpress.

I suspect the chain ring is a counterfeit version of the NZ Lekkie Ring.  The teeth on the ring are alternately thick and thin to match the wide and narrow gaps in the chain links

I also replaced the original Bafang plastic gear cover with a red alloy Lekkie plate.

At this point I had become sufficiently confident with the bike and my own physical condition to take it on a cycling trip around Taiwan towing a trailer.

The trip went well although my posterior did suffered on a daily basis from the saddle. 

On my return to Perth I purchased an expensive "Brooks" UK leather saddle believing the marketing hype "After a few weeks the saddle will conform to your shape and you will feel like you a riding in a hammock"    Numerous applications of leather softener and six months later the saddle is now better than the original.  Although I still get a sore posterior  

My first Aliexpress handlebar bag started breaking apart at the seams during my Taiwan trip.  Probably because I attempted to place too many heavy items into it.

I've now replaced it with a larger bag which is insulated

I use it to carry my wallet, power banks and snacks.

Two Aliexpress water bottle holders have been mounted to the frame top bar.  I've attempted to locate them on various parts of the bike eventually settling on the top bar.

At some stage during my cycling I buckled the front wheel.  The local wheel maker assembled a new one using the same strong rim and spokes as the rear wheel.

During my second trip to Taiwan the Bafang brake sensors I had fitted to the original brake levers started to separate.   On my return to Perth the entire brake lever assembly was replaced with a new assembly which had the sensors integrated.

I also damaged the power controller when my cycling glove caught the edge of one of the buttons breaking it.  The power controller is part of the display mechanism which meant I needed a new display. The one I selected has recessed buttons on the power controller and a coloured display

Power Controller, manual throttle controller and bell.

During my first Taiwan trip the phone holder broke.  I made a temporary repair using a condom (found beside the bed in the motel - I didn't take one with me!).  I replaced the holder with something more substantial.

Another thing that broke on my first trip to Taiwan was a cheap bike stand.  It was replaced with a much stronger version.  Although it had to be modified to fit the bike

The two latest modifications are the replacement of the Bafang cranks and the original plastic pedals.

I'm rather pleased with the current status of the bike.  I can ride up to 80km and still have 60% charge in the battery.  I'm almost amused when I look at the bike and realise the only original components on it are the frame, brake callipers and seat stem. 

Are there any planned future modifications or alterations to the bike?  Probably not!  Although I am wondering if I will need a front rake and panniers if I decide to take a long trip involving camping.  I should do a test pack to see if all the gear will fit on the rear.

Dave,

Thanks for the tip.  I'll do some research on availability in the UK.

Ade,

I suspect you will have identified there are plenty of e-bike options.   My opinion is the high price of manufactured e-bikes is being driven by the 'economies of scale'.   That is; too many manufacturers for a small market.  Aftermarket e-bike conversions are cheaper because the same motor fits many bikes.