How We Transformed a RadWagon 3 into a Mid-Drive Powerhouse

We're excited to share a standout project where we transformed the RadWagon 3 cargo e-bike by Rad Power Bikes. Our objective was to replace its standard 750W hub motor peaking at 40Nm of torque with a Bafang BBSHD mid-drive system with 160Nm of torque. This decision was driven by a customer’s desire to access the power and efficiency of a mid-drive motor, without spending the nearly $10,000 typical of new models on the market. By starting with a relatively affordable RadWagon 3 and upgrading its components, we achieved superior functionality for less than half the cost of a brand-new mid-drive e-cargo bike.

Project Overview and Installation Insights

The RadWagon 3 originally came equipped with an aluminum frame, rigid steel fork, and a 1 × 7 drivetrain, suitable for our upgrades. The bike had already been upgraded by the owner with Magura MT5e hydraulic disc brakes, offering robust stopping power perfect for the increased demands of a more powerful motor.

Key Installation Steps and Tips:

• Motor Installation: We installed the Bafang BBSHD motor, a 120Nm increase in torque compared to the original hub motor, providing enhanced responsiveness and the increased torque handles steep inclines with ease and efficiency.
• Battery Fit: Fitting a larger 52V battery within the frame’s limited space presented a challenge. We opted for a custom-made 52V 17.5Ah battery from Affordable Ebikes, designed to fit snugly within the existing downtube space, maintaining the bike’s streamlined appearance.
• Wheel Replacement Challenges: After removing the hub motor, finding a rear wheel that met all our requirements was difficult. The wheel needed to be 26 inches in diameter, have at least 20mm internal width, freewheel compatible and support 32+ spokes for increased strength. Despite the challenges, we found an ideal match with a 49N Rim/Disc Brake Nutted MTB/Urban Wheel from Fortnine.
• Brake Sensor Compatibility: A specific challenge we encountered was adapting the brake sensors for the upgraded Magura MT5e hydraulic brakes, which came with 2-pin red HIGO connectors. The Bafang kit uses 3-pin yellow HIGO connectors. To ensure functionality, we modified the connectors, allowing seamless integration without impacting brake performance.
• Cable Management and Lighting Installation: We utilized the bike's existing internal routing channels for a clean and professional setup, hiding new cables within the downtube and under the fender for the rear taillight. The new lighting kit not only improved visibility but also integrated smoothly with the brake sensors for enhanced safety features.

Performance and Customer Feedback

The upgrade dramatically enhanced the bike's performance, especially in terms of power and speed. The mid-drive motor allows the RadWagon 3 to ascend hills at 30kph, double the capability of the original setup. The new motor placement also improved the bike’s balance, an essential factor when loaded with cargo.

Our customer expressed immense satisfaction with the conversion, stating:

"I did a swap from the stock 500W hub motor on my RadWagon 3 to a Bafang Mid Drive with Jason. The bike is so much more fun to ride now with good balance of power and braking. Highly recommend reCycleBikes for their honest, quality work and reasonable prices."

Conclusion

This RadWagon 3 project exemplifies how strategic upgrades can transform a standard e-bike into a high-performance machine. If you're inspired by this transformation and considering similar upgrades, remember that planning, customization, and choosing the right components are key to success.

Share your e-bike projects and experiences with us using #reCycleJourney, and stay tuned for more from our series. For those in the Vancouver lower mainland looking for expert e-bike builds or maintenance, consider reCycleBikes for your next project.