2022 Farley

Joined
Aug 7, 2022
Messages
17
First time out of the shadows to post up my build that you all helped to make a reality, lots of great info to streamline these builds (thank you for that!).

Took a 2022 Trek Farley and did the deed that you are all so familiar with and installed a BBSHD (unlocked from Johnny Nerdout....good dude btw!!) and 52V/17Ah battery from EM3EV.

Got the bike back in August and though I ordered the parts during that period, supply chain disruptions stretched this build out over 3 months. I got bored waiting so I spent plenty of time just enjoying this silly fat bike.

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Shimming the motor just off the stays was pretty straightforward but because the bb on this bike is 122 mm I didn't have room for the locking nut.
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The cheap stamped tool was ok for test fitting the motor but proper torque down requires real tools. I couldn't find the right sized lock/spindle socket so I just made my own.
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One of my biggest concerns for this build was how to secure a 10 lb battery to the frame in a way that will stand up to the beating I'm gonna throw at it. Luckily this frame has three contact points on the down tube and an additional two mount points on the seat ube for bottle cages. If I make use of all five contact points I should be able to stabilize the top heavy battery and keep it from destroying the stock rivet nuts on the down tube.

First I used a quarter inch thick of rubber sheet to raise the battery mount up off the frame and create some vibration damping between the two hard parts. Then I built a couple of plates to create a 'quick disconnect' upper mount.
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The battery slides into and locks to the base mount and mates up with the upper mount nicely. It's super secure now!!
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Since I have plans to do quite a bit of winter riding with this bike I wanted to protect and insulate the battery from the cold elements in hopes to get the most out of each charge. I decided to install a triangle bag which will also help to clean up the look of the bike by hiding most of the wire harness. I couldn't find a bag that filled the triangle in my extra large frame but this one from Amazon was pretty close and the price was right. https://www.amazon.com/Moosetreks-Mountain-Trail-Frame-Medium/dp/B07CXDV2CL/ref=mp_s_a_1_3?crid=30316J6K9ZHAD&keywords=Trail+Mountain+Bike+Full+Frame+Bag&qid=1668271454&sprefix=trail+mountain+bike+full+frame+bag%2Caps%2C542&sr=8-3

Using my 1/2" grommet kit I made several passthrough points for the wire harness.
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Then it had to install the battery mounts inside (and thru) the bag.
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A quick test fit of the battery and everything is coming together nicely. I can still reach all buttons and easily install/remove.
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I'm still messing around with ideas for a motor support for added insurance while I'm out pounding the bike on single track rock gardens. For now I'm testing a simple bracket that bolts onto the front derailleur frame mount and is hidden nicely behind the chain ring.
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Maiden voyage of about 10 miles of rocky foothills results in all smiles!! Motor hasn't moved, power delivery was exceptional, and drivetrain shifting was super smooth. I forgot to mention that I swapped out the stock 1x12 (to preserve it) and went with an 8 speed 11-34T setup to get the best chain line. I was concerned that I'd have low enough gearing too pull my 225 lb butt up 25% grades but those concerns were quickly put to bed after this test run.
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We got our first snow for the season this week here in the Tahoe area and though I have a few more bits like fenders that have yet to show up, I couldn't resist.
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It's almost impossible to wear out an Aussie...but he's looking winded after chasing me for the last hour. Good stuff!!
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Battery looks very secure!

Great welding job on the socket spanner!!! :thumb:
 
Nice conversion. The 8 Speed setup should last longer that the 12 Speed too. Interesting Lekkie hardware to address chain-line issue too.
 
Snow is firming up nicely up in Truckee so I was able to get some more testing in. Added some fenders from Portland Design Works and they were very effective on the flats where I reached 18-20mph. I was concerned the rear fender would be a problem with my dropper post but never an issue! I did drop a chain once after a deep snow get-off but I also think a frozen derailleur contributed to it as well. The only other thing to note is that....my goodness, snow sucks up the power!!! I did a 10 mi loop w/ 1200' of vert and I used about 50% of the battery!!! Wow, wasn't expecting that. Oh well, I enjoyed every bit of it.
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Good day, I hope you've been able to get some trail under those tires. Question regarding your battery mount: how did you secure the top plate onto the top of the battery case? Epoxy?
 
pwd said:
Good day, I hope you've been able to get some trail under those tires. Question regarding your battery mount: how did you secure the top plate onto the top of the battery case? Epoxy?

I sure have!! Half dozen rides over the last couple weeks, mostly in snow. I'm just floored by how much fun this thing is under these conditions.
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Regarding the battery case mount, I initially thought of using a two-part epoxy like JB weld but I was concerned about low temperature impact resistance & vibrations. Epoxies actually improve in bond strength at lower temps (approaching Tg) but w/o special additives they don't do well with cold temp impact resistance. Since I had some in my chest, I went with E6000 which uses a solvent based butadiene rubber and is excellent for extreme temp flexibility/vibrations. So far so good 👍
 
Thanks for the info and nice photo :bigthumb:
 
I'm doing a fat bbshd build for someone and was wondering if your motor has rotated/loosened at all since your initial install.
 
I'm doing a fat bbshd build for someone and was wondering if your motor has rotated/loosened at all since your initial install.
Not one bit! As a matter of fact I have about 100 miles of some pretty technical and very rocky riding and just got back from a set of rides in Moab. All I've done is properly torque (no loctite) the nut and it's been great!
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Nice photographs. One suggestion. Hold your phone sideways. The world is horizontal. My computer monitor is horizontal. I am so smart, I don't need a smart phone.

Look at the aspect ratio settings in your phone. Yours are too long and thin. Read:


Common aspect ratios in still photography include:
  • 1:1
  • 5:4 (1.25:1)
  • 4:3 (1.3:1)
  • 3:2 (1.5:1)
  • 5:3 (1.6:1)
  • 16:9 (1.7:1)
  • 3:1

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