Custom Electric Surly Pugsley
by Volt Electric Bicycles

This is a one-of-a-kind electrified Surly Pugsley that you will only find at Volt Custom Electric Bicycles. This fat tire mountain bike will climb hills like a champ and has an estimated top speed of 25-30 MPH. It can do an estimated 30 miles on one charge.

A little bit about the Surly Pugsley

Pugsley was created to go where standard “all terrain” bikes flounder. The floatation and traction afforded by large-volume, low-pressure tires can get you over and through otherwise unrideable terrain…sand, mud, wet rocks and roots, ice and many kinds of snow. There are other fat bikes out there toady. Lots of them use equipment we originally developed for the Pugsley. The Pugsley has not suffered in popularity with these new offerings, because it works exceedingly well and, hey, it’s fun too.

The Pugsley frame has 135mm-spaced horizontal rear-loading dropouts with a derailleur hanger. This means you can set it up with a derailleured drivetrain or an internally-geared hub. Run it with a singlespeed freewheel or a fixed cog. You have lots of drivetrain choices.

The stock fork accepts a 135mm rear mountain hub, just like the frame. This makes it easier to install and remove the wheel (a big tire on a big rim benefits from a wide opening), and it allows front and rear wheel interchangeability. This means you can have the ability to carry another full gear cluster, a singlespeed freewheel, or a fixed cog on the front wheel. And should something go wrong with your primary drivetrain, you have the option of swapping wheels and continuing on your journey or retreating to a place where you can make necessary repairs.

Pugsley is available as a frameset and as a complete bike. The complete bike sports a nice mix of components chosen for their durability and value. This year we changed the complete bike features Marge Lite rims and Microshift thumbshifters, which work well especially when wearing mittens. The front hub is now our Ultra New model, and the front derailleur is now a more modern and sensible D-type, and we include the adapter clamp even if you just buy the frame. We added an extra small (14˝) frame size too this year, and changed the color to keep things interesting.

CHOOSING A MOTOR
Theoretically, we can build a bike to suit any of your range requirements. We offer gearless brushless motors custom made for us using large heavy duty copper windings and the gearless motors have no internal moving parts, so it is inherently more reliable. The “HI TORQUE” Electric Bike Motor provides approximately 30% more torque than any other motor we sell. All motors are rated at peak power output. Motors are all REAR motors as they are much safer with higher output levels and do not require dual-torque arms like a front motor. Plus, ride dynamic is greatly increased with a rear motor versus a front motor. The “HI SPEED” Electric Bike Motor is the motor you want if your main priority is speed on flat ground! If you are an off-roader, and routinely climb hills, choose the “HI TORQUE” or “CROSS COUNTRY” Electric Bike Motor instead.

CHOOSING A POWER PACKAGE
Higher Wattage (W) means more power! The 1000W system has a bit over 1.25 hp and is a great, basic motor for medium assist up medium grades. This system has a top speed of 20 MPH. The 1500W systems all employ a 52v battery system that can provide more than 2 hp and can handle very steep grades.  These packages can go up to 27+ MPH, and are the best choice for hill climbing! The 2800W system has more than 3.75 hp, and the NEW 4500W system features a brand new, wider motor with 5mm wider neodymium magnets and stator, can deliver OVER 6 hp! ALL SYSTEMS ARE FOR OFFROAD USE ONLY ABOVE 750W! Please check your local laws and regulations. Most models can be made on road legal with cycle computer.

The 2000W is, in our opinion, the best balance of performance, hill climbing, durability and price.

CHOOSING A BATTERY
Our new batteries are a special Lithium based tri-metal blend of Nickel, Manganese, and Cobalt, or Li-NMC for short. These batteries are 25% lighter than the outgoing LiFePo4 batteries and deliver consistently higher voltages across the voltage range which translates into more speed and range.

CHOOSING A CHARGER
By default, any battery system you purchase from us will come with a 2A Charger. This means that if you have a 10Ah battery system, it will charge in about 5 hours. You can choose to upgrade to a 4A charger which is twice as fast and will charge in half the time (2.5 hours for a 10Ah pack). Finally, the fastest charger we carry is a 10 Amp Charger which can charge in about 1hour. (or 3x as fast as the standard charger).

CHOOSING A THROTTLE
This is totally up to the end user. It comes down to personal preference, do you prefer a motorcycle type twist grip throttle or a thumb throttle? 95% of our bikes come with a twist throttle if your shifters are thumb throttles.

CHOOSING A FREEWHEEL
Choose the number of speeds on your freewheel based on the number of rear speeds on your bike. Most 21 speed bikes use a 7 speed freewheel, 24 speed bikes use an 8 speed freewheel, 27 speed bikes use a 9 speed freewheel, and 30 speed bikes use a 10 speed freewheel.

CHOOSING A RACK / BAG SYSTEM
If you have a basic battery system that is 10Ah, the standard rack is fine. However, if you would like a stronger, sturdier rack, opt for the upgraded rack that is rated to carry more weight.  We also offer our exclusive Frame Bag battery system. The frame bag allows a much more central weight balance.  These bags are hand made in the USA with exceptional attention to detail and make for an incredible ride! The new bags for 2013 are waterproof, feature lockable storage, and hardshell sidewalls to protect from punctures. At this time, our half-frame bag can fit up to a 90V 12.5Ah NMC battery system!

TORQUE ARM
For systems below 2000W, a torque arm is optional. Anything above 2000W, it is definitely recommended. The torque arm will save your motor from falling out/spinning off your dropouts.

E-BIKE DIAGNOSTIC CYCLE COMPUTER
The E-Bike Diagnostic Computer is a very useful tool for your electric bike and is highly recommended. It delivers vital information about your electric kit at your fingertips, such as: speed, distance, relative battery level, RMP, torque (Nm), and efficiency. It also allows you to limit your power level to your desired level so you can save battery. It also has a 3-speed function which allows you to set your speed (low, medium, high). With this computer, you have the ability to make any kit street legal!

**Range estimates are a maximum figure based on FLAT ground, no pedaling, 170lb. rider, 18-20 MPH steady cruise speed.**

 HI-TORQUE GEARLESS MOTOR

Performance Stats:

    • 1000W System: 20 MPH (37V High Performance Li-NMC)

*19 Mile Range, battery weight: 5.6 lbs, Motor Weight: 12.6 lbs

    • 1500W System: 27 MPH (52V High Performance Li-NMC)

*27 Mile Range, battery weight: 7.8 lbs, Motor Weight: 12.6 lbs

    • 2000W System: 28 MPH (52V High Performance Li-NMC)

*27 Mile Range, battery weight: 7.8 lbs, Motor Weight: 15.9 lbs

    • 2800W System: 33 MPH (63V High Performance Li-NMC)

*32 Mile Range, battery weight: 9.5 lbs, Motor Weight: 15.9 lbs

    • 3500W System: 39 MPH (78V Ultra High Performance Li-NMC)

*37 Mile Range, battery weight: 11.7 lbs (Li-NMC) Motor Weight: 15.9 lbs

    • 4000W System: 44 MPH (90V Ultra High Performance Li-NMC)

*44 Mile Range, battery weight: 13.4 lbs (Li-NMC), Motor Weight: 15.9 lbs

    • 4500W: 46 MPH (90V Ultra High Performance Li-NMC)

*44 Mile Range, battery weight: 13.4 lbs (Li-NMC), Motor Weight: 16.9 lbs

 

 CROSS COUNTRY GEARLESS MOTOR

Performance Stats:

    • 1000W System: 27 MPH (37V High Performance Li-NMC)

*19 Mile Range, battery weight: 5.6 lbs, Motor Weight: 12.6 lbs

    • 1500W System: 33 MPH (52V High Performance Li-NMC)

*27 Mile Range, battery weight: 7.8 lbs, Motor Weight: 8.9 lbs (Geared) or 12.6 lbs (Gearless)

    • 2000W System: 34 MPH (52V High Performance Li-NMC)

*27 Mile Range, battery weight: 7.8 lbs, Motor Weight: 15.9 lbs

    • 2800W System: 41 MPH (63V High Performance Li-NMC)

*32 Mile Range, battery weight: 9.5 lbs, Motor Weight: 15.9 lbs

    • 3500W System: 46 MPH (78V Ultra High Performance Li-NMC)

*37 Mile Range, battery weight: 11.7 lbs, Motor Weight: 15.9 lbs

    • 4000W System: 50 MPH (90V Ultra High Performance Li-NMC)

*44 Mile Range, battery weight: 13.4 lbs (Li-NMC) Motor Weight: 15.9 lbs

    • 4500W: 52 MPH (90V Ultra High Performance Lithium)

*44 Mile Range, battery weight: 13.4 lbs (Li-NMC), Motor Weight: 16.9 lbs

 

 HI-SPEED GEARLESS MOTOR

Performance Stats:

    • 1000W System: 30 MPH (37V High Performance Li-NMC)

*19 Mile Range, battery weight: 5.6 lbs, Motor Weight: 12.6 lbs

    • 1500W System: 36 MPH (52V High Performance Li-NMC)

*27 Mile Range, battery weight: 7.8 lbs, Motor Weight: or 12.6 lbs

    • 2000W System: 40 MPH (52V High Performance Li-NMC)

*27 Mile Range, battery weight: 7.8 lbs, Motor Weight: or 15.9 lbs

    • 2800W System: 45 MPH (63V High Performance Li-NMC)

*32 Mile Range, battery weight: 9.5 lbs, Motor Weight: 15.9 lbs

    • 3500W System: 50 MPH (78V Ultra High Performance Li-NMC)

*37 Mile Range, battery weight: 11.7 lbs (Li-NMC) Motor Weight: 15.9 lbs

Every Electric Bike we make at Volt Electric Bicycles are custom made to your specifications.

Contact us to today to discuss options and pricing.
Email: voltbicycles@charter.net

10 Comments on “

  1. I am as well…but why are all these manufacture’s so shy about disclosing prices?
    Why is it so difficult to purchase a bike?

  2. Ok, i ‘ m ready fo r my fat tire e bike. The hi speed 2800 w , 27 gear, , motorcycle style control with the computerhow much shipped to upstate NY?
    Thank

  3. yes I would like to buy 2 wheels with the cross country gearing and 1 of the speed gearing with 3 hi range batteries. Thx!

  4. Why is the Hanebrink so wide?  #1 it needs to be to accommodate large tires for that luscious fat bike riding, #2 if it weren t so wide it would not be able to mount a full sized hub motor in the frame so nicely without interfering with the  crank arms.

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