DIY Mountain Bike / MTB Mudguards / Fenders

DIY Mountain Bike / MTB Mudguards / Fenders - Intro

I was a little pissed at the thought of having to spend £7 on a piece of plastic, which is literally no bigger than the lid off an ice cream tub.

But here's the thing, why not buy a tub of ice cream, eat it,  and use the plastic there in to make a set of DIY mountain bike / MTB mudguards.

This design of front mudguard is a far sturdier mudguard than the zip tie offerings, and unlike the down tube style guards has the advantage of moving with the wheel when you turn around a corner.

The rear option sees you spending money on a rear luggage rack, which weighs next to nothing and using that as a mount point for salvaged plastic. A rear rack is so so handy. If you don't like handy and prefer trendy then you are reading the wrong blog.

DIY Mountain Bike / MTB Mudguards / Fenders - Ingredients

It doesn't have to be ice cream, just keep an eye out for a any sort of suitable plastic, and lets face it we are drowning in the stuff, it needs to be quite thick and rigid. The sort of plastic you might get from a 25 litre container of something (cooking oil?), or the lid off a 10 litre paint tub that sort of thing. Nearly all of the below you could probably find lying around.

Hint: Before you throw stuff away start taking it apart and keeping the nuts, bolts and screws, as they come in handy.

• Snips or Jig Saw
• Strip of Steel
• Drill Bits
• Rivets or Small Nuts and Bolts
• Plastic (HDPE Preferentially - Number 4 Plastic)
• Star Nut Sized to Stem
• Zip Ties

Now right about now, you might think that £7 doesn't sound so good, if you don't have this stuff already then, the outlay may not be worth it, although it will set you up for future projects. You could do this in a community work shop. 

DIY Mountain Bike / MTB Mudguards / Fenders - DIY Front Mudguard

For the front mudguard will need a piece of plastic around 30cm long and  10cm wide. You cut this in the shape of a podgy wine bottle. You then place a 10cm length of strip steel, or hammered flat steel tube, over the thin under an rivet in to place. Finally you drill an 6mm hole in the end of the strip about 2cm from the outside end.

Hammer a stat nut in to lower end of your fork steerer tube. You then bolt the front mudguard to the underside of the steerer tube. Done.

DIY Mountain Bike / MTB Mudguards  / Fenders - DIY Rear Mudguard

At this point you might be thinking you don't want a rear luggage rack. . .  

But you soooo do want one: You can get a rear luggage rack on eBay for £10 with postage (which is less than some mudguards). This opens up all-sorts of options, for off-road touring etc. If you are thinking bike packing, well you can still strap trendy bags to it, that would otherwise be mounted further up under the saddle, where they will raise you centre of gravity. For practical types, you can add a pannier to store water, food, and clothing. I recently did a stretch of the south downs way (off-road) carrying 2 litres of water, lunch, clothing and tools, in a pannier it worked a charm, I can swap the same bag on to any of my other bikes, in 5 seconds. 

Any hoo. 

Simple cut a piece of plastic the same width as you rack's underside and secure with zip ties. I you had a long enough piece you could extend this down to the chain stays, but I have found the the piece jutting out at the back as shown in images is fine. 

Preliminary Ecological Appraisal 


Sunlight and Daylight Assessment

Shimano Hub Dynamo DH3D32 Review

Shimano Hub Dynamo DH3D32 Review

This Shimano Hub Dynamo DH3D32 is the cheapest hub dynamo I could find that is suitable for disc brakes.  It is your typical Shimano offering i.e. perfect.  This is a 6 bolt version but there is also a centre lock version.

The  DH3D32 has the standard Shimano connector which is easy to install, although the stripped wires need to be just the right length.

The DH3D32 dynamo will illuminate the front light at a fast walking pace. It is advisable to buy a light with a stand light, this not only stays on whilst you are stopped, but smooths the flicker which nearly all dynohubs create when using a lamp without a standlight.

If you are currently using rim breaks why not buy this anyway, it will have a higher resale value, and allow for easy future upgrades.

Update: 2024 have just moved this on to another building, and is still going strong. Using it with a Busch and Muller Cyo 80 Lux. Perfect. 

Preliminary Ecological Appraisal (PEA)

Environmental Consultants Bristol

Schwalbe 13F Inner Tube Review

Schwalbe 13F Inner Tube Review - Intro

A few years ago I purchased some Michelin C6 inner tubes to run with my Schwalbe Big Apples (26 x 2.35). They are a wide tire and I feel  that a wide tube is required. The Michelin C6 is a very thick walled down hill tube, but the valve had sheered off, so I have replaced with a Schwalbe AV 13F, which is a tube designed for use with wide tires.

Wiiiider than the aaavergage tube!

To be clear Schwalbe's Inner Tube Selector Tool , suggests I can use standard width or wide tubes.

Schwalbe 13F Inner Tube Review - First Impressions

The tube is very light for its size. The wall thickness is less than a typical tube, which means this tube can weigh just 185g. A little under double a regular tube. By comparison a down hill tube of the same diameter will weigh 300g +.

The rubber is very supple, and the valve is re-enforced with thicker materials in this area.

I have found these thicker tubes to offer no better protect against thorns than a normal thickness tube. Which leads me to think I will not get any more punctures using a light weight tube.

I I were in to extreme riding, then perhaps a pinch flat would be a problem. But for me that is unlikely.

Re-enforced valve tube interface

Schwalbe 13F Inner Tube Review - Do You Need a Wide Tube?

No this is the main question for me. I suppose the answer in a nutshell is NO, you do not need a wide tube. Many inner tubes offer wide ranges 1.5" to 2.5" for example, which would suite my tires.

But as with so many things bike, we are all of us tinkerers and experimenters in search or our version of perfection.

To my mind a standard high quality tube will be stretched to near its max width when used in a wider tire. Some questions this raises:

1 - Does this mean that the air pressure in the tire is pushing out against the elasticity of the inner tube, rather than the wall of the tire?

2 - Does this mean that the rubber held taught, is more prone to punctures?

3 - Does this mean that tube is less supple? Effecting rolling resistance?

For me these questions and the negligible worries they create are reduced by using a wide tube designed for wider tires. And for the sake of £3 extra per inner tube that is worth it for me.

Schwalbe 13F Inner Tube Review - Conclusions

So I don't really need this inner tube, I am not sure if it offers any advantages, but I feel more comfortable using it. Which in my book is worth something.

Environmental Permit Application London

Rigid Forks for Commencal El Camino

Rigid Forks for Commencal El Camino - Intro

The Commencal El Camino Frame has lots of mounting points for fenders / mud guards, racks etc. and as such make a great rough stuff touring, utility frame. To increase loading option still further, you may consider rigid forks from surly or salsa. But what length of fork is right.

Rigid Forks for Commencal El Camino - Axle to Crown

The axle to crown measurement is the one to look for. This is some time listed as AC or A/C. It is the measurement from the axle to the crown of the fork, the crown is where the crown race sits.

The Commencal El Camino full bike is supplied with a RST Blaze 27,5" Fork, the  axle to crown measurement for this fork is 495mm.

Rigid Forks for Commencal El Camino - Sag

When you hop on a bike with suspension forks the forks squash down a bit. This is called sag. Racing bikes are set to have about 10% sag, whilst non-racing bikes might have 30% sag. An average of 20% is usually used. So if you apply this sag figure you are looking at a length between

• 445mm (10%)
• 396mm (20%)
• 346mm (30%)

Bear in mind that the radius of a 650b wheel is 325mm. So allow for clearance, fenders, and mud space. 

Rigid Forks for Commencal El Camino - Shopping

Most forks available from surly or salsa are at least 460mm in length. It is better to go longer than shorter, perhaps adopting the 10% sag figure from above. 

So based on the above we would be looking at the below fork options.

• Surly Instigator (447mm) - Lots of mounting points. 
• Thorn Mount Tura (430mm) - No disc brake. Lots of mounting points.
• Thorn Nomad Disc Fork (420mm) - Excellent Choice. 
• Gusset DJ26 Fork (430mm) - Cheap. But no mounting points. 

Rigid Forks for Commencal El Camino -  Good luck.

Have fun and cheerio. 

Environmental Consultants London

Environmental Permitting

Environmental Permit Applications  

Using a 3 Speed Switch on an EBike

Using a 3 Speed Switch on an EBike - Intro

When using an EBike normally the speed is controlled by:

• Pedaling (with assistance from the motor)
• Use of Throttle

So why would you require a 3 speed switch to control the speed as well? 

Using a 3 Speed Switch on an EBike - Types of 3 Speed Switch

There are lots of different types of 3 speed switch available, the most simple is shown below. 

Some are slightly more complex . . . 

The above model incorporates a "walk" mode and also  power level indicator for batteries. 

Using a 3 Speed Switch on an EBike - Why Use One?

When using pedal sensors the speed switch can be used to control the amount of exertion put in by the rider, over a certain speed you will have to do the work . . so you:

1. Get more exercise
2. Use less battery

On a bike with a throttle, the reasons are a little more complex. There are two main reasons for having one . . . 

1 - Helps control speed.

If you have ever tried to travel across rough ground whilst holding a throttle in a half open position, you will know that generally your hand wiggles around, cause the throttle to move and the bike to surge forward occasionally, because your wobbly hand is moving the throttle. 

By using a three speed switch you can set the speed at a low speed, and fully open the throttle. This makes for a smoother low speed experience on rough ground. 

This is also useful for kids, as you can limit the maximum speed they can use. 

If you find that the motor pulls the bike along at a speed which is too fast for you to pedal, then a switch can be used to slow the bike down to a speed where you can provide useful pedal assistance. Installing a cheap switch is easier and cheaper than changing the gearing of a bike. 

2 - May limit peak wattage and protect motor in steep climbs.

This reason depends on the controller you have installed, but the premise holds true for most controllers that allow for connection of a 3 speed switch. 

When you choose a lower speed, you are selecting a lower voltage, for example a 48v controller in low speed may deliver 24v.

All controllers have a maximum current that is supported. My controller for example has a 15 amp upper limit. So in low speed I have restricted my motor to 360w. And so in a steep climb using maximum amps, and therefore maintaining maximum torque there is a reduced chance of overheating the motor. 

This is of use when non technically minded people are riding an e bike in a hilly area. "You need to be on speed setting 1" for example is a lot easier than saying "third throttle ".

Questions I do not know the answer to:

When normally entering a steep hill at full speed, the bike will slow down as it climbs the hill. Without using a speed controller what is happening inside the motor? 

Are 48 volts and up to 720w trying to turn the motor, with non movement resulting in buildup of heat?

or

Does the controller adjust the voltage according to speed, ignoring throttle position, so as to reduce wattage, and reduce chance of overheating?

If you would like to learn more about the relationship between torque, amps and wattage < read this. 

Using a 3 Speed Switch on an EBike - Do they work on any ebike.

It is not the bike, that is important, but the controller. Look at the controller's wiring diagram. . . is there a connector labelled for "3 speed switch" or "speed switch"? If yes there is a good chance you will be able to use one.

The 3 speed switch that I purchased, worked fine with one controller but not with another.  

Using a 3 Speed Switch on an EBike - Notes 

It is worth noting that is you have an e bike that goes 15mph, the 3 speed settings will result in the following speeds:

1. 17.5mph
2. 15.0mph
3. 12.0mph

So you have to be careful that installing a switch pushes you over your max allowable speed for road use. In my case I uninstalled my switch because in the high speed setting it made the bike illegal.

Using a 3 Speed Switch on an EBike - Conclusion

Part of me thinks that these switches are surplus to requirements, they serve no real purpose because the bikes speed can be controlled via the throttle.

BUT they do add in a extra option for controllability of the bike at a very low cost. 

Fire Prevention Plan 

Environmental Permit Applications  

Busch and Muller Lumotec IQ Cyo T Review

Busch and Muller Lumotec IQ Cyo T Review

Busch and Muller Lumotec IQ Cyo T Review - Intro

After building a DIY longtail cargo bike I needed a front light so I moved my Busch and Muller Lumotec Lyt Senso Plus  on to the cargo bike and purchased a top of the line Lumotec IQ Cyo T to fit on my upright bike. I have been so happy with the otehr busch and muller lights I have bought I didn't mind parting with the money, I suspected it would an excellent light, and it is.

Busch and Muller Lumotec IQ Cyo T Review - First Impressions

 What a lovely piece of kit. Build is very solid switch feels like it is meant to last. Metal bits are stainless steel.

Busch and Muller Lumotec IQ Cyo T Review - Features

The Lumotec IQ Cyo T has got one main powerful LED light source for lighting the road, and four intensely bright LEDs that provide visibility (ie so cars can see you etc.). Two of these 4 LED are supported by a standlight so they stay on when you are stopped. Even these LED running on standlight provide visibility for 3 - 4 meters.

The Lumotec IQ Cyo T is packed with features. It has a daylight sensor which automatically switches between modes, depending on how dark it is.

Stuff off of the box:

• 5 x the minimum level of brightness required by german road safety regulations.
• LICHT (light in german) 24 with daytime running lights - 4 super bright signal LEDs = optimised visibility for other road users.

There are 3 settings for the  Lumotec IQ Cyo T, I have yet to under stand these fully . . the german translation in the instructions is a bit weird.

T -  Head lamp in mode "Daytime Running Light" (DRL) best visibility for for the bicycle during the day or during foggy weather. The driving light in the DRL mode is sufficient to meet german traffic regulations even during teh night and is often more than sufficient. Ideal visibility is guaranteed when cycling on well light streets.

S - During daylight the headlamp runs with full daytime running lights . During dusk and darkness the headlight automatically switches to night mode.

The build quality is very sturdy. Switches feel smooth on operation.

Busch and Muller Lumotec IQ Cyo T Review - Performance

A bright white flood of light will fill the road ahead of you for around 20 meters, because the main headlight is so powerful there is no need to focus the spread of the beam, and as such there are few bright spots / dark spots as is the case with less powerful headlight.

Even the 4 Small Lights Below the main headlight are bright enough to ride by.

The daylight running light (the row of 4 no. LED below main headlight) are extremly bright, and even 2 of these LEDs running on standlight provide visbaility for 3 - 4 meters.

Above pic shows the standlights on the Busch and Muller Lumotec IQ Cyo T which are very bright, again blow but exposure perhaps a little long.

Side view. . .  .not as good as I would have liked. You should compare these to the lumotec lyt before purchasing. I think the lumotec lyt may give better side on visibility.

  

Desktop Study

 Flood Risk

Busch and Muller Lumotec IQ Cyo T
Reviewed by Kermit Green on 2013
Rating: 4.5