Completed AWD E-bike (2 Motors)

Here is the completed All-Wheel-Drive E-bike for use on St Thomas, U.S. Virgin Islands.  St Thomas has some of the most extreme hills in the entire US.  Elevations go from the Caribbean Sea at 0 ft (0 m), to the highest point: Crown Mountain (Saint Thomas) at 1555 ft (474 m) The island is only about 14 miles long by 5 miles wide so most of the land mass is vertical.  If there ever was a need for an all-wheel-drive bicycle, this is the place.  I completed this cargo bike build last night and took it out for the maiden voyage this morning.  The Bafang BBSO2 mid-drive motor was used as the primary with pedal assist but whenever I encountered a really steep hill, I would throttle on the front hub motor in low gear to help pull me up the incline.  This worked remarkably well and I was able to cruise effortlessly all the way to the top of St Thomas at a comfortable 12 mph without breaking a sweat.  The front hub motor never reached temperatures greater than 52C (126F), which is well below the cut-off temperature.  The small sine wave controller and cables fit easily into an Ortlieb saddle bag with plenty of room for a few tools and a spare tube.  The front disc brake was a bit tricky.  I had to dish the wheel to allow 10mm of extra space on the non-drive side to fit the disc rotor.  Even after allowing for the extra spacing, the bottom caliper bolt needed two M6 washers to scoot the caliper out a bit so the rotor would line up correctly.  This install takes some finessing and a good measure of cussing but the end result is worth the effort.  I opted to run the twin systems from two separate battery packs for redundancy.  In the event that I break a chain, I can always scoot back under front hub power and on long level trips the second battery gives me a total of up to 100 miles of cruising distance on a single charge.

Below are some photos from my ride.

Shift Gear Sensor

Shift sensor to allow safe gear changes under load.

E-Bike Torque Arm

Tail lights 10 LEDs on each side.

Tail lights 10 LEDs on each side.

St Thomas view

St Thomas from Mafalie Rd.

Twin E-bike Displays

The cockpit showing both color displays.

Bafang BBSO2 Mid-Drive 750w motor.

Bafang BBSO2 Mid-Drive 750w motor.

Front hub double torque motor

Front hub motor with 203mm disc rotor.

E-Cargo Bike on St Thomas hillside.

E-Cargo Bike on St Thomas hillside.