The video above shows just a selection of our high quality components. There are many more quality parts that go into a DryCycle.
Starting with the all Aluminium (Grades 6063T6 and 6081T6) Frame, which is made from over 150 parts that are precision cut, drilled, shaped and welded together, then joined together with almost entirely stainless steel nuts, bolts, fixings and bearings, all DryCycles really are built to last and perform well.
For example, we use massive 20mm diameter stainless steel bolts to hold on the rear swing arm suspension to ensure they won't bend even after bumping through numerous potholes, as well as powder coated steel, 25mm diameter, hollow rear axles and commensurately large 47mm outer diameter stainless steel bearings, which are just some of the 30+ bearings throughout the vehicle. We don't buy cheap bearings either, all of our bearings are sourced from major UK suppliers to ensure that they will last for a long time and give smooth operation all covered by our 2 year 20,000 mile warranty of course.
And you don't just need to take our word for the solid design and build of our vehicles, as we've had Bureau Veritas test two DryCycles to make sure.
The tests included the strength of the framework and endurance requirements.
Normally Electric Assist Pedal Cycles (EAPC's) are tested to EN15194. The EN15194 tests ensure Bicycles are robustly made within certain design parameters, given the basic normal shape of a Bicycle.
We can’t test our product specifically to EN15194 as our product is not Bicycle shaped (Two wheeled, with front forks, saddle to sit on and a diamond shaped frame), and no standard exists for a 4 wheeled EAPC such as ours. So we had to first design our own standard using EN15194 as the basis for this, before then having our vehicles tested by the independent testing house Bureau Veritas.
The tests involved completing cycles of up to 100,000 repetitions of fatigue tests on various components, simulating years of use, to ensure they wouldn’t weaken or fail over time within the set parameters, as well as strength tests to check that impacts on the wheels and other components wouldn't break them under normal use, as well as other general tests.
Beyond the parts that we designed and made ourselves, we've also ensured that the parts we buy in are to the highest standard as well. For safety and convenience we use the very top of the range components from Shimano for our motors (E8000's), batteries (Also 8000 series), derailleurs and cassettes (Deore XLT), and of course the Di2 electronic gear shifting. Given the increased weight of our vehicle selecting the very best from the cycling world ensures the longevity and efficiency of those parts.
The plastic that we've selected for the bodywork is formed by a specialist UK based vacuum forming Company who have CNC milled the Forming Tools you see here from solid Aluminium Billets to ensure consistent accuracy in the panels.
The type of plastic we have chosen is used by other vehicle manufacturers due to it's long term UV stability. UV damage is the main cause of embrittlement in plastics when used in external environments.
We use acrylic capped ABS, which is probably the most expensive of the vacuum-formed options, but is also the best at resisting UV damage and is proven for use outside.
For similar reasons, as well as optical clarity and strength, we use Polycarbonate for the clear plastic panels. These are formed to the required shapes and then coated externally with a hard wearing Automotive grade protective coating to give far greater scratch resistance. This is the type of coating (UVHC 3000K) that is used on headlight covers for cars, which obviously need to remain relatively clear from scratches even after stones hit them at motorway speeds, and some cars have small rain wipers running over them of course.
We really have spared no expense.
We've gone to a number of lengths to make owning and running a DryCycle as easy as possible, as we want our customers to be riding their DryCycles not spending time looking after them. We also offer customers a two year warranty that includes parts and labour.
To start off with, for any chain driven vehicle the chains will stretch over time. Our early designs were missing chain tensioners for each of the 3 chains, and without these we were needing to periodically mess around with spanners and nuts in order to tension those chains like motorcycle riders need to do every 500 miles or so. Needless to say, we didn't want our customers to do this. So we're supremely confident when we say that you'll never need to tension a chain on a DryCycle, because all of the chains have spring loaded chain tensioners and the rear most chain, that drives in both directions, even has two tensioners to ensure that the chain is always perfectly tensioned without you needing to do it. You will need to replace the chains once they wear out or break of course.
For those few times when you do need to carry out maintenance to the Drivetrain, such as replacing a broken chain, the DryCycle is designed to be tilted onto it's back to access the underneath for maintenance without the need of a ramp or similar as a car would require. There are also two removable panels in the footwell that can be removed if you need easy access to the chain or any other component at the front of the vehicle.
Another issue with chains on a normal bicycle is that they are exposed to the elements, so fairly quickly they get covered in road muck and rain water washes away any oil on them, requiring you to add more oil on a frequent basis if you want them to operate properly. With a DryCycle all 3 chains are fully enclosed, protecting them from road debris and rain water. This means that you'll only very infrequently need to oil and clean the chain (every 2500 miles or 3 months). Even though it's infrequent we've also made sure that oiling the chain is as simple as it can be, that merely involves tipping the DryCycle on it’s back and applying widely available 'dry conditions' bicycle chain oil at the designated locations.
The forward/neutral/reverse gearbox also requires oil changes, though as a sealed unit this is even more infrequent at every 5,000 miles, or 12 months, you’ll need to unclick the undertray to do this, and remove the gearbox which is held in place by 8 bolts.
All of the bearings we use are sealed, or have rubber boots or other coverings to protect them from water and debris and are all covered by our 2 year 20,000 mile warranty.
The lights are all LED so will rarely need replacing in the normal lifespan of the vehicle.
The electric motor is a sealed unit and does not require maintenance, it will eventually need to be replaced/refurbished when it wears out, but it's covered by our two year 20,000 mile warranty so if this happens within the warranty period we'll do it for you.
Likewise, the differential is a sealed unit that does not require maintenance and is also covered by our warranty.
Brake pads and discs will naturally need replacing as they wear out. The front pads are accessible through the front wheels without the need to remove the wheels, accessing the rear pads requires removing the undertray, which clips on and off, and can be done with the DryCycle resting on it's back.
Tyres will need replacing as they wear out, but since the wheels are only held on one side, rather than both sides like a normal bicycle, then with the use of a small axle jack to hold up the axle, you can do this without even removing the wheel.
Almost all of the fixings are made from stainless steel, the framework is Aluminium and the body is plastic, so corrosion is only possible in the very small number of places where we haven't been able to use such materials, and such parts can be easily replaced when they eventually need to be, of course if this happens during the warranty period and you haven't done anything wrong to cause the issue then naturally you are covered.