The Ogre has landed ...

John L.

Member
After a long wait, my Surly Ogre BBS-02 build is finally done (well, almost. I'm still tinkering with a few minor things)! I took it out for a couple of short test rides today on some hills that usually kick my butt, and I'm definitely happy with the result! The Bafang really smooths out the hills, and I must say that shifting is much smoother than I had expected. I'm looking forward to putting the bike through its paces in the next few weeks, and will post updates as I go. I'd like to post a picture, but it says the file is too big. How do you post a jpeg on this site?

Here are the basic specs:

Stock Surly Ogre (XL).
Bafang BBS-02 500w kit with 44-tooth chainring, 48v battery.
SP Dynamo hub.
Supernova E3 headlight/tail light.
Avid BB7 Disc brakes. (stock)
Shimano Deore 10-speed cassette (stock).
Schwalbe 29-in Big Apple tires.
Jones Loop H-bar handlebars, ergon grips.
Cane Creek stem riser.
Cane Creek Thudbuster seatpost.
Brooks B-17 saddle.
Surly rear rack.
Acorn med. saddlebag.

 

George S.

Well-Known Member
If you are using Windows, at least 8, you can open the file in Paint (right click the jpeg) and then resize to around 800 by whatever. Save, maybe with a different name. I think Paint is part of the package. Then just "Upload a File".
 

J.R.

Well-Known Member
Congrats! Surly has some envious bikes, look forward to reading your reports.
 

John L.

Member
Thanks George S. Here's the photo.
 

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George S.

Well-Known Member
John, It's shocking how quickly the BBS02 has become a mid-drive standard. I ended up with a Surly fork, for a front hub conversion, to get some strength. It's smart to aim for some better parts, especially if you may go over 20 mph. That's almost the EBR Community "Tribute Package", with the BBS02 and the suspension seat.

If you learned anything notable along the way, let us know. Great to see the picture. I think people who go into the BBS02 knowing the chain can be a little 'hot' do OK. The early people with the full power versions got some nasty surprises. At least that is their story on YouTube. :D
 

John L.

Member
George, I've learned quite a bit from the EBR community, for sure. Lots of great information and ideas and a very welcoming environment. Nobody tries to make anyone else feel "stupid" for asking questions.

I mostly invested in this as a hill-climbing commuter/errand runner/grocery getter (with cargo trailer). I've owned other Surlys and they make a quality product that can be configured a wide variety of ways. I also like a cro-moly steel frame for durability and its "feel." The thud buster seat post seems to make a big difference in terms of comfort (at least as far as initial impressions go). I may do some further modifications down the road, as I learn more and experiment. Depending on how the 10-speed cassette and chain holds up, I'll either leave the drivetrain as is or I may decide it's worth it to invest in a NuVinci CVT hub down the road. So far, it seems pretty easy to shift if you just take it easy when you shift. I got the optional motor cutoff button from EM3EV, but haven't had to use it yet. And, you can squeeze the brake lever slightly to cut off the motor too. Most times, I just stop pedaling til the motor cuts off, shift, then start pedaling again. Seems to work fine without mashing the gears, as long as you don't hammer the pedals during this process. Since I'm not planning to go off-roading or using it primarily for speed, I hope I don't have issues with gear-mashing, chain drop or breakage. Nevertheless, my plan is to carry an extra chain in my saddlebag just in case. Let the journey begin!
 

Go-Coo

Member
Hi John,

took at peek at your build. I wonderd why the housing of the BaFang does not rest flush against the down tube?

With higher torque it may well work it's way up there I guess...

Regarding an extra chain in the saddle bag: could a mini chain tool and a link save some weigt?

What other Surlys do you ride?

Cheers,

Go-Coo
 

John L.

Member
Hi Go-Coo,

To address your questions: The Bafang housing sits just below the down tube, but not right against it. I hadn't really noticed, to tell the truth. No problems, and it hasn't worked its way closer after about 100 miles of riding. I haven't felt the need to put an extra chain in the saddlebag yet, though I did buy an extra one to keep in my garage. Your idea is certainly a lower-weight option for chain emergencies. My experience so far is that the complaints about shifting have been somewhat overblown. It's fairly easy to shift without mashing gears or unduly stressing the chain. It may be different for people who like to go super fast and shift under load at high speed, but that ain't me.

BTW: Here's a picture of my Ogre ready to haul my Surly Ted trailer loaded with bike helmets for delivery to a kids' bike safety class. Worked like a charm. Everybody was blown away that I didn't need a car to haul so much stuff.
Trailer1.2.JPG
Trailer1.2.JPG
 

Go-Coo

Member
Hi John,

Cute trailer! Do you have a picture showing how the coupling attaches to the rear?

Curious G-Coo
 

John L.

Member
The Surly cargo trailers use the same hitch system as the one that is used by the Bob Yak trailer. Bob makes a skewer for the rear hub that fits most bikes, but the Surly Ogre (and the Surly Troll) have eyelets for the trailer hitch bolts built into the rear triangle of the frame for greater strength. One of these bolts (Surly calls them "Bob's Nuts") bolts into each side of the frame's rear triangle near the dropout, and the Surly (or Bob) trailer attaches to those. The photo I have shows the left side that also includes a trailer hitch for my Croozer light duty cargo trailer (which fits on the rear axle skewer). So, depending on the load, I can use one of two cargo trailers. The Croozer will carry up to about 80 lbs, the Surly trailer is rated to 300 lbs.
 

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Ravi Kempaiah

Well-Known Member
The Surly cargo trailers use the same hitch system as the one that is used by the Bob Yak trailer. Bob makes a skewer for the rear hub that fits most bikes, but the Surly Ogre (and the Surly Troll) have eyelets for the trailer hitch bolts built into the rear triangle of the frame for greater strength. One of these bolts (Surly calls them "Bob's Nuts") bolts into each side of the frame's rear triangle near the dropout, and the Surly (or Bob) trailer attaches to those. The photo I have shows the left side that also includes a trailer hitch for my Croozer light duty cargo trailer (which fits on the rear axle skewer). So, depending on the load, I can use one of two cargo trailers. The Croozer will carry up to about 80 lbs, the Surly trailer is rated to 300 lbs.

Brilliant setup.
 

Go-Coo

Member
Hi John,

thanks for the pic. So that huge aluminium bolt is a Bob-nut, ok.

So long Sherpa, and happy riding!