Dobro.velo колица - building a small cargo bike

So… I moved house a couple of months ago, to the outskirts of the Styrian city of Graz, halfway up a hill along the Mur river. Views are magnificent and I really enjoy the tranquility up here. Being a bit separated from the infrastructure of the city also means that the logistics of my day-to-day life had to change. The daily commute is about 12km with a 200m vertical (down in the morning, up in the afternoon) which is a really good distance and effort. It becomes a bit of a challenge though for the weekly shopping or for transporting random chunks of cast iron that have appeared via the post man to the workshop. I found that I was using my car way more than I liked to admit. Finally, I have a use case for an electric cargo bike!

A couple of years ago, I was involved in the prototyping for a small cargo bike from Switzerland, the “monoPole Toolbike” and I really liked the concept: A cargobike that can fit a standard eurobox container but is not longer than a regular 28” bicycle. The general design however is trademarked, and I also didn’t just want to copy it so I had a look at my tubing stock and came up with a version of my own.

20/24” wheels, slightly forward secondary headtube, split TT that continues into the seatstays, a bafang 1kW motor and a 3x3 geared hub that can tolerate up to 250Nm of input torque!
My brother mentioned that he was getting increasingly worried about the reliability of his 1980ies Suzuki motorbike so he is getting a toned down version with a 500W hub drive (he lives in flat northern Germany)
First task was to make an extension to my frame jig to accomodate the extra head tube

Two is almost batch production :wink:

Quite a few mods were needed for the chainstay jig to fit this arrangement:

Dropouts are laser cut sliders with brazed on stainless friction surfaces and connect to the stays via stainless bearing balls

Yay, it’s starting to look like a bike!

A friend came to visit me in the workshop. He has a fancy camera and knows how to use it to his (and my) advantage:

Test fit of the cargo rack went ok, aluminium tig welding not so much (first try went into the scrap directly…)

Back from powder coating, I couldn’t be happier with how the color came out!

Then the friend with the camera came for a visit again:

Couldn’t be happier with how it came out! Some little things like cable management are still to be done, and connecting light seems to be quite a lot more involved than on an acoustic bike (I’m not good with electrons…) but overall I’m looking forward to taking part in #carryshitolympics :wink:

(колица is Serbian by the way, sounds like “kolitsa” and means wheelbarrow)

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:heart_eyes:

Looking so good in that deep red!

Is the Eurobox fixed to the platform in any way? or does the platform just lock into the base of the box? How’s the power? does it do skids and wheelies?

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So rad! Thanks for sharing.

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Right now the box is fixed with zip ties. But the cargo rack leaves a lot of room for improvement anyway, so there is a V2 on the horizon. And it would be really handy if one could “click” the box in and out of place easily…

Power is plenty, it can still go 20km/h up a 12% incline without me pedaling :wink:
I have to get familiar with the firmware on the controller, then I can probably make it do skids and wheelies…

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So. Cool! Great job on the design. I like the twin top tubes and rectangular tube yoke. The battery mount looks quite robust compared to bottle bosses - great idea.

I haven’t seen any 3X3 hubs over here in the US yet (though VPL carries them…) I’ve had a bad experience so far with Alfine 8sp/11sp, but this seems like an interesting alternative, especially for electric builds. Is this your first time using this hub?

Thanks for sharing!

Hi Colin, thanks for your kind words!

The battery mount was designed because the idea of mounting a ~6kg lump of lithium to some bottle bosses in a 40x0.9mm tube made me a bit uncomfortable :wink: It makes me feel a bit safer on this death machine (I can make it go almost 60kph if I wanted…)

The 3x3 hub was a good but also expensive choice. Apart from the NuVinci it is probably the only geared hub rated for these kind of input torque figures. It has a torque support that feeds into the brake mount instead of some 10mm wide keyed surface inside a QR dropout (like the Alfine/Nexus and many others) and it can be configured in many axle standards. It is beautifully made and well documented. I was given access to their OEM portal where all the CAD 3D models can be downloaded.

Assembly and setup went smooth, and so far it has worked flawlessly. Can’t give any long term feedback yet though.

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