This project was a fun one to do. The goals were a 24-inch-high seat, electric assist, accomodate 6'5" rider and yet be extremely adjustable, easy front entry, hand rails to assist with entry and exit. There was a lot of custom fabrication here and we are sure it won't be the last time we build something like this.
We started out with our Extended Quad as the base.
The first step to getting the height was to build up some custom 24-inch wheels equipped with Schwalbe Big Apple 2.35 tires all the way around.
In order to make entry easy, we needed the front of the seat to be even with the frame's cross arm. That meant an extra-extra-long boom that needed bracing. So, we combined the bracing with a custom seat riser to get the rest of our seat height.
The seat bar also made the perfect mounting place for the EcoSpeed motor kit.
The support rail system that wraps around the seat is height adjustable in the front and back to aide the rider in entry and exit.
Because of the seat height and forward position, the main challenge ended up being the steering system. After trying a few ideas, we ultimately converted the steering to a tiller linkage-style setup.
We started by making a rail support across the cross arm and machined out a pivot assembly to hold the handlebars. You can also see the adjustable mount for the support rail on the right.
The handlebar pivots are ball-bearing supported so that they can be laterally stiff while offering very little resistance.
For the linkages to the handlebar pivots to the main linkage assembly we used ball joints instead of Heim joints to get us the range of motion that we needed.
While the electric drive is capable of high-speed, there was a concern that should the batteries ever die the gearing needed to be low enough to climb any hills. With that in mind, we equipped this Super Quad with the Schlumpf Mountain Drive. This two-speed transmission will give Don the low gears he needs.
Shown here without the locking bolt, this modified seat clamp allows the seat to be placed anywhere along the upper support bar.
Using the Swingrip mount we placed a mirror on the support rail.
The Ecospeed clamp on attachment is used to tension the front pedal chain. That is done by loosening the two clamps and sliding the motor assembly rearward.
If you wish to remove the battery case all the plugs are in one location and easily disconnected.
The seat angle is adjusted by changing the location of the bolts on the rear seat stays.
The rear drive axle on the Quad is our own "posi-traction" differential which uses two freewheels to maintain traction while allowing the outer wheel to move freely in a turn. This prevents the slippage that occurs with a geared differential on loose or slick surfaces.
This Quad is equipped with BB7 brakes on the front and rear. The Avid BB7 brakes have excellent stopping power and are easily adjusted without tools.
The Super Quad features our new (2012) rear brake system. This setup allows the rear wheels to be removed without the need of removing the brake calipers.
The connection point on the steering linkage can be rotated to set the neutral position of the handlebars.
The support plates can be removed if the upper support/boom needs to be removed.
All the idlers are heavy-duty TerraCycle Sport idlers. The chainline is ran throughout without any sideways flexing.
The Ecospeed is a middrive electric drive. It is mounted in front of the Alfine transmission to provide maximum power to the rear wheels. The lower idler position is slid forward to adjust the chain tension.
The center arms can be rotated forward to adjust the handlebar position.
The Throttle is mounted so that it is easily used by the right thumb.
The right brake lever controls the rear brakes.
The left brake lever controls the front brakes and has a locking pin so the Quad doesn't roll while parked
The central steering pivot has our Steering Modification Kit to decrease the steering radius.
The Shimano Alfine transmission has 8 speeds.
The support rail height can be adjusted in the front. There are three positions.
In the rear, the support rail can be moved along the bar and adjusted with the U-bolts.
The seat mesh is comfortable and breathable.
The EcoSpeed motor is 1000W. More than enough power to climb hills and go fast!
This elastomer is used to minimize flexing during high torque of the motor.
We went with the Sun Rhynolite XL rims. They are super strong and pair perfectly with the Big Apple tires.
The Avid BB7 brake calipers can be adjusted without any tools using the red dials on either side.
The arm on the handlebar pivot puts the linkage tierod into the proper position.