The Bullitt Build
1. Battery and Battery Box
2. Cargo Box
4. Front Motor & Wheel
5. Rear Motor & Drivetrain
6. Bits & Pieces (You are Here)
I’ve hit all the big ticket items. Now for the bits and pieces that may be of interest.
Fahrer Panel Bags and Tools
The Fahrer bags were a late addition. Partly because they cost so damn much. I was not willing to spend the money until I finally realized my idea for a MOLLE panel, trimmed to size, with bags attached was just more effort than I felt like going to get the same result in DIY fashion.
For me, the point of these bags was to move my tools out of the cargo area. I seldom need to mess with/rummage through them so I wanted them in a place that kept them out of the way. At the same time, there is a fair bit of money wrapped up in this toolkit, not the least of which are the battery powered air pump and the ridiculously expensive but wildly useful Knipex pliers/wrench. For a bike that gets left outside of a store a lot, I wanted to be able to easily, routinely remove these bags for carry inside with me.
I settled on putting the tools in a bag that fits inside of the bag. Specifically I used one green and one brown Condor Field Pouch, which have handy top-grab handles for pulling the bags easily and quickly up and out.
Two of these bags, in two contrasting colors – green and brown – so I know which is which on sight.
Ordinarily these Condor bags are used for something like a 1L water bottle, but they are a near-perfect shape for form-fitting directly inside the Fahrer bag. The different colors help me remember straightaway whats in each pouch.
The contents of my tool kit fit along my usual lines: I want to be able to use what I am carrying to do just about any typical field repair. I like to work with full-sized tools, so I am not at a disadvantage on the side of the road where life sucks bad enough already if I’m broken down.
Worth mentioning are those two black disks in the pictures above. Those are not emergency field rations (unless its REALLY an emergency). Those are two regulation hockey pucks. Solid, dense rubber blocks. What the hell for? Set one each under the Bullitt’s 2-leg kickstand. Now either the bike’s front or back wheel is up and off the ground by several inches, depending on which way you tilt the bike. Instant quickee service stand.
I’ve heard its tough to fit a rear rack on the back of a Bullitt. There are M5 bosses built into the dropouts, but it can be a challenge to utilize them as the brakes get in the way on the drive side.
I found an Axiom Streamliner 29er DLX rack fits perfectly.
UPDATE: Mar 22 2022. I actually used this slightly different Axiom rack that was sold as the Streamliner DLX. Nowadays this same rack is marketed as a 29er rack and now includes the extra-strong center mount (I used a spare from one of my Fatliners) as well as the stay mounts. The current Streamliner is narrower and sold strictly as being compatible with 700C tires (although I have one of them on the front of my Envoy that fits 26×2.8″ tires just fine).
Its lower mounting arms move the rack 4cm out and further back to ensure there will never be any heel clearance issues. Its strong – rated to a whopping 50 kg, although I don’t know about that. I’d say 25 kg is still pushing it, but as racks go its very strong and can stand up to any reasonable level of use. I use it to hold the more delicate items that come from the store. Bread, chips and such. Or if I am just expecting a large or heavy load I may attach the panniers so I can clean out my cargo bay so its one big empty box.
But the rack needs just a bit of surgery to fit. Note in the picture below I did just a bit of filing to give clearance for the brake adapter bolt. Without this small adjustment it won’t clear.
I also used the center mount from an Axiom Fatliner rack (I have several of them). It has about – literally – four or five times the material in it as the Streamliner center support. I did have to drill new engagement holes for it. Maybe I can get away with that 50 kg rating after all.
Kicktail / Reinforcement / reflector
I have done a reflector/kicktail before on many bikes as sort of a signature mod. I usually take a 6″ x 18″ street sign, stand on it, grab an edge and bend up until I have a lazy L shape of roughly 35-40 degrees. I drill some attachment holes and the result is a 1-piece rear rack deck plate. The kicktail ensures no mud comes up at the rider, ever. Coupled to other measures I like this approach better than a traditional fender.
To add utility, I also cover the underside of this kicktail in 3M 3432 Red Micro Prismatic Reflective Tape… Exactly the stuff used in manufacturing municipal street signs in the USA. It so happens that a few years ago I scored a 12″ wide roll of this stuff at a small fraction of its regular retail price, so I can just unroll a bit of it and slap it onto the back side of the kicktail and voila… the world’s largest red bike reflector. I guarantee you I am visible to an overtaking automobile even if I didn’t have my steady and blinkie taillights fired up.
But my usual racks are fat bike racks where a 6″ deck plate works in conjunction with mounting panniers. Not so with the much more narrow ‘normal sized’ tires of the Bullitt. I needed just a narrow strip on the top of the rack with channels on each side to allow the pannier hooks to be engaged.
So I used a narrow 2″ strip of aluminum flat bar in the full length that I needed, and then bent that bar up to the desired angle. Following that, I bolted a second, full-rack-width 4″ x 12″ piece of aluminum flat bar onto the strip to make the kicktail. Line the back side with tape and functionally the job is done. However, since I had discovered a green duct tape that is a near perfect color match for the Larry vs. Harry ‘Lizzard King’ green, I wrapped the upper surfaces of the rack with it for what I think is a nice look.
So… the 2-piece kicktail… in the end I decided it wasn’t working for me. The giant red reflector was a big winner as they have always been, but the need to do a 2-piece thanks to the narrower rack caused issues that just grated on my OCD (just kidding I am not diagnosed with this condition). Being 2-piece, it jiggled around some while riding simply because it was heavier than its predecessors. Also, the metal plate rested directly on the rack and rubbed, scraping off the protective powder coating. Trying to pad that with 3M 2228 mastic was only marginally effective as the stuff inevitably wore down and mooshed away under the force of the metal edge bearing down upon it.
To solve this issue I re-thought my approach. I discarded the wide flat plate. Next I cut down the rack deck plate so it was just long enough to intercept all spray coming up off the tire. Then I lined the now-exposed rear with the same prismatic red reflective street sign tape used on the full kicktail. In the front, I affixed a swatch of orange prismatic tape to provide another reflective surface. To finish it off, after filing down the upswept end so there are no sharp edges, I took the added precaution of making a bumper with a layer of that same rubber 3M mastic.
With this change, I hit the sweet spot. The bobtail still keeps water off of the rider, it still has a large reflective surface and I quickly grew to appreciate the shorter profile. Godzilla is already about 8 feet long before that tail comes into play, and I don’t miss bumping into the kicktail as I walk around the bike.
Rear Thru Axle
Surprisingly, sourcing a proper rear axle was a major pain in the ass. The rear axle is a 12×166 (12mm in diameter by 166mm in length). The ’12’ part is standard stuff. The ‘166’ is a little unusual but still not a dealbreaker. Mix in the required P1.5 threading and thats where Google and Amazon searches go off the rails.
After a fashion, I ended up finding two of them. I ended up using the cheap one and have kept the fancy one in reserve.
The Cheap One:
Dymoece brand 175mm with 19mm thread length. Its exact specs are written right on it in the picture below. I was surprised at how well this was machined. Its 175mm length is too long, but I had a 3mm thru axle washer in my parts bins. Putting that on sizes the axle so there are 2-3 rows of threads visible coming out the derailleur side. Perfect. Everything lined up on this one from the thread pitch to the slightly longer thread length to allow the use of the washer. I like this axle because it is tool-less. I am already carrying hex keys and they’ll work just fine if I need to remove this axle roadside.
The Fancy One:
DT Swiss model 2160062210. This is a model that has a snap-on lever – that is just a glorified hex key – for removal. It looks nice on the bike, and you can remove it so nobody walks off with the thing. For me, since I am already carrying hex keys, I don’t need another one hanging off the end of the axle. I also like the fact that – on a bike that will sit out alone in public – no lever means no invitation to passersby to remove said axle. Still… its a DT Swiss part so its top quality.
Good luck trying to find details on this thing without looking deep across multiple web sites. The Amazon product listing gets it all wrong, calling it a 142mm length (which is correct for the internal dimension) and saying absolutely nothing about thread length or pitch.
Here’s what it really measures out to: 12x171L, thread pitch is 1.5 (it had better be) and thread length is 13mm.
With the shorter length and shorter thread pitch, it fits the Bullitt frame and dropouts perfectly without a washer, and the thread overhang out the drive side is minimal.
As usual, I cobbled together something from parts and raw materials. Here’s what the finished product looks like from a few different angles.
This is a pretty non-traditional fender set up that does the same job as full coverage fenders without the full coverage. We’ll first cover the materials, and then we’ll discuss the assembly as a whole.
Gather Your Materials
Every bike builder should own some of this stuff: Flexible black cutting board. Unfortunately the black stuff seems to be off the market for the moment, or I am just not looking in the right places. Here is a link to something made of similar material to give you an idea of what I am talking about. What you want to do is replicate the same base material that is used for flexible MTB mud fenders. Once you have that you can cut that raw material to shape as needed.
Next, I used two of these front fenders, that I interwove together, facing each other, so they made a single longer fender. total cost for the pair – which are the core of the fender project – is US$12.84 delivered.
I created the rack deck plate and bobtail with a 1/8″ thick, 2″ x 24″ piece of 6061 aluminum flat bar stock – sold as a remnant – that cost me $8.00 on Ebay. That is way cheaper than normal. Here is a 48″ long piece that is 1/8″thick x 2″ wide. You can cut down to your needed length. Save the rest for your next project. You can go much wider than this for a rack deck plate, but I decided I wanted to go narrow for reasons that will be clear when you see the next item.
I continued to use the paint-matching duct tape that I found by accident across all parts of the rack. If your Bullitt is not the older, brighter Lizzard King color you will want to go with something different. If black works for you then Gorilla Tape is probably my favorite overall material for this kind of work, and in fact I use it here, as described below.
Put the ‘fender’ together
Its not really a fender, but rather a series of pieces that do the job of a fender.
First of all, there’s the rack deck – the bent-up piece of aluminum flat bar. Its length is determined by how long it needs to be to intercept all water spray coming up off the back wheel. I also want enough of a ‘tail’ so I can add enough reflective tape so it is a sufficiently big rear reflector. I used a relatively narrow piece that is 2″ wide. Why?
I wanted enough free space on each side so I could hook panniers to the rack. I *could* have done a full coverage deck – which would have allowed me to use a wider bobtail, and then used a router or hand files to cut out slots for pannier hooks. Frankly… it was easier to do a narrow piece and then follow up with …
Tape. The color-matching tape is nothing more than a wide series of strips folded over onto themselves to make a 2-sided sheet fully as wide as the entire rack deck. Then I bolted the aluminum flat bar on top of it. To allow for the hooks to be popped onto the top of the rack tubes, I simply took scissors and snipped the tape where there is a crossbar, to allow it to fold down when I clip panniers on. This is a bit cheesy, but it got the job done. If some time down the road I have some time on my hands and about US$30 I will cut a full width bar and slot it so its prettier than what is there now.
The rack and bobtail thus do most of the work keeping water coming up off the wheel. Now we have to deal with water coming forward. That is accomplished with the cheapie, doubled front mud fender. It is attached with small green zip ties to the seatstays, and its length in the back lifts up and contacts the rack deck. So… no water is coming forward past that. The front half of this fender also comes down and butts up against the seat tube fairly low, so there is very little area uncovered. But lets cover that too.
To deal with that last bit, I used the cutting board material and snipped out a rectangular length that is as wide as possible while still staying out of the way of my legs and the crankarms (look for it, installed, in the pics). I poked a couple of holes in the right spots and simply screwed this length of ‘fender’ directly to the frame using the two M5 bosses that are already there for fender mounting, on the back of the seatpost.
On the front, I cheated and found something I could just buy and install.
Godzilla uses a Greenguard-belted Schwalbe Super Moto X tire in 20″x2.40″ size. This is larger than most tires – in fact its a hair under being too large to fit the frame. Most fender solutions will not fit.
The SKS Rowdy 20-24″ fender set provides the solution. I shelved the rear fender and used only the front half of the front fender. The front mount without the fender attached is shown below.
Since the fender slides onto the mount bayonet via a firm interference fit, I keep the fender in my toolbag. If I need it I just slide it on. I like to be able to see the tire when riding, as part of my general need to be over-informed of every aspect of the bike as I go down the road.
In addition to it not fitting the bike, there’s no need to use the rear half of the front fender. The front of the cargo deck shields the rider from any splash coming up off the back of the tire. I did add some waterproof rubber tape to the frame at strategic locations to ensure it is a fully sealed face to splashing water.
I am using the generic Larry Vs. Harry steering dampener. I found the bike had a horrific speed wobble prior to adding the side panels, which almost completely eliminated said wobble. It only reoccurred on certain downhill road segments where there were repeated road undulations… that set up just the right harmonics for it to happen again. Installing the dampener and setting it to its lowest level cured the problem forever.
I use Jones bars to alleviate pain from pressure on my wrists that came from getting hit by an inattentive motorist in 2017. Their 45-degree angle works wonders. They also give me a long grip area that lets me change positions, and lots of real estate to attach all manner of gadgets. An AWD ebike with one throttle for each thumb, dual PAS panels and dual displays, headlights, a dashcam, missile launchers etc. benefits from the wealth of mounting points available.
I also use two sets of Wolf Tooth Fat Paw grips. 1 and 1/2 grips per side. The extra diameter works well with my hands and thanks to those wrists, I need the extra padding. I cover the 2-piece-per-side grips with a wrap of silicone plumbers’ tape that keeps them grippy but not sticky. If I tear up the grip tape somehow (this happens rarely) I just wrap on another layer.
Long ago I gave up on trying to find a light that suited my needs, that I could wire into my main ebike battery. Instead all of my lights have their own internal, rechargeable batteries. Once a week at the office I charge them all on the same day, via a USB hub that is a part of my office garage gear.
I use my lights as daybright, daytime running lights and night use. The need to have the lights day-visible means I am going brighter than most folks’ lighting setups.
My lighting choices are informed by the knowledge that blinkie lights are the best to improve the ‘conspicuity’ (yes thats a word) of a rider, but they inhibit a motorist’s ability to track motion. So I use a combination of steady lights and blinkies, front and rear.
Out front I use a pair of Niterider Lumina Micros for my main headlight beams. I split my headlights into two widely separated beams for the same reason cars do it. It makes for a wider beam pattern than you can get even with a dual-bulb single headlamp.
In between the two steady headlights is the front version of the Knog Big Cobber. This is a pricey light, but its also probably the brightest, smartest front blinkie you can get your hands on. It actually has an app that lets you program its modes, and I have mine set to ‘eyesaver’ mode coupled to their econ mode (short but intensely bright) blink. The Cobber lights from Knog shine in a 330-degree arc. So you want the eyesaver mode to keep from having that blink coming back at you.
Out back, I have another Knog Big Cobber as my blinkie. Again it is set to ‘econ’ mode which is an intense, sharp, short blink. This time I let it ride for its full 330-degree illumination. That blinks light to the ground, to the motorist and up into the red reflector of the bobtail. Hopefully they’ll see me.
To aid said motorist in tracking my motion, I have two Knog Blinder Square lights, set to a steady illumination of the outer half of the light.
Running the light half-strength like this lets it last the full week as I like to charge everything together on Friday.
After literally decades of riding first toe clips and straps, and later clipless when they were introduced into the market, I have been riding flat pedals and Five Ten Free Rider sticky platform pedal shoes for the last couple of years.
I decided to go back to clipless not too long ago, and I have found the Funn Ripper pedals to be amazing. Their spring loaded cleat mechanism – the cleat sticks up and makes cleating in ridiculously easy – is a wonder. Highly recommended. I’m using Giro Rumble shoes which let me cleat in, or get off the bike and walk into a shop or wherever comfortably without clackclackclacking on the pavement.
As you can imagine, being locked into the pedals again made for an exciting transition period, and I managed to fall over at an intersection within 24 hours of making the switch. But once that little reminder was hammered home, I haven’t done it again.
So… Thats That
It seems I’ve come to the end of this somewhat tedious breakdown of all things Godzilla – The Big Green Bullitt. If I come up with any more I’ll amend this post. But, honestly I’m happy this series is done as it lets me get on with other projects I have been looking forward to, but can’t begin because this monstrosity remained unfinished.
12 thoughts on “Larry vs Harry Bullitt – Project Odds & Ends”
Wow, such a thankless service you have provided with exquisite documentation and links. That is some next level “paying it forward” for the unknown souls out there who may be embarking on a similar path. My leg powered bullitt is in the early stages of conception but I’ve learned so much more here than what can be found scattered all over the internet. Bravo.
Thanks very much for your kind words, David, and I am glad you found it useful. While this series was a little bit of a drag because it turned out to be so long, I do enjoy doing this. Not as much as riding the bike though 😉
i found you when i was building out my mongoose. i had the same path, wanted inexpensive, made it super expensive with all my upgrads. your build sheets and pages were amazing for that build. but i’ve been seeing it’s limitations and wanted to go another direction
i just decided to pursue getting myself a bullitt, and damn, who’s the first person to show up in my google searches? right here. thanks again for all this info on your bullitt build, it’s going to help me a ton. lots of legwork here helping me out. cheers
The Bullitt ended up being my absolute favorite daily driver and still is to this day. Good luck with your project!
Amazing! Do you have the full parts list somewhere? Would love to know what this cost you all in.
I had the benefit of a well-stocked spare parts garage thanks to my other projects, so my real-time cash outlay was well below total project cost. As you see in https://talesontwowheels.com/2022/05/01/how-to-build-an-ebike-from-scratch-planning/ I use a build sheet for project management. I created a ‘public’ version for the Bullitt build at an earlier time when I was going to use it for that article. It is in the following link. Hold onto your socks as the final number is eye-watering, but it is all-inclusive and shows ancillary items (duffel bag) as well as other items I added much later (like the Viscoset substitution for the steering dampener) : https://docs.google.com/spreadsheets/d/1qN6FMU9d6rLZRpfXobeo7qZtlnZWWBSLkzPetBqzbwo/edit?usp=sharing