Custom DIY Modular Bike Rack Seat (Part 2-Upholstery)

This is my solution for creating comfortable modular seats for the rack of my KBO Ranger electric cargo bike. The design and technique used here could be adapted for any bike rack that is big enough and has enough weight capacity for at least one person.
If this helps you to create something I would love to see the result!
This is part 2 of 2, which covers creating the cushioning and upholstery.
Check out KBO's bikes - kbobike.com/pr...
Note: I was not given anything to promote this bike, however I did sign up as an affiliate so if you do purchase something through my link I will receive a small commission.

[@danazotter5717]

Looks good! Loved your helper too!

[@daysarelongyearsareshort5979]

Thanks, she rocks!

[@SCP-SAM]

Great share.... ty

[@daysarelongyearsareshort5979]

Thanks for watching!

[@capphapp]

It would be great to see how the bike handles two kids on the two seats.

[@daysarelongyearsareshort5979]

Hi David, handling isn't effected too much assuming your children already know how to ride bikes (don't fight a lean when you're turning). With my two girls I will only do short trips with both because together they exceed the rack weight limit. It's less noticeable than it would be with a regular bike as the percentage of total weight for the child passengers is lower. Myself and the bike weigh a total of 257lbs so at the rack limit the added weight only represents 32% of total weight. Granted it handles *better* without that weight, but I haven't observed any difficulty with them on the back and I do ride more conservatively than when it's just myself. The motor is powerful enough that I don't really notice any reduction in performance, but battery usage is increased.

[@capphapp]

@@daysarelongyearsareshort5979 Thanks for the reply. I am really curious about power and hill climbing. My real question though was about the comfort for your kids. It is not a huge space for 2 people, even small ones. Do you have any problems with your heals running into the feet or knees of the child in the front seat you built?

[@daysarelongyearsareshort5979]

Gotcha, it's a tight fit for my 7 and 10 year old so really depends on the kids sizes. There's a guy on the FB KBO group who regularly rides with 3 kids! If I were to be regularly transporting both kids I might adjust the seat positions. In the video 1 of 2 I mention at the beginning that I changed from a 24" board (which is the length of the rack) to a 36" solid pine 1" board for extended space. I'm in Florida so I don't have lots of hills, but when going over the Ringling bridge (65' rise, I think 5% grade) I don't have any slowdown with my 1 daughter (70lbs) and dog (20lbs). The sustained rate of the motor is 750 watts, but the peak is much higher. The controller will regularly pull 22 amps when accelerating and at about full capacity (54v) that's 22x54=1188 watts. Once you drop down to say 45 volts that reduces to 22x45=990 watts.

[@daysarelongyearsareshort5979]

Forgot to mention, despite a tight fit for them, they're still comfortable and no issues with feet or knees getting into my space

[@capphapp]

@@daysarelongyearsareshort5979 Thanks that is exactly what I was looking for. It seems like all of the cargo bikes are a bit under powered with 750 watt peek motors. Then the Ranger came out with a stronger drive system but with a rack that is short by cargo bike standards. My kids are still small so your seat pattern might be perfect. Thanks for the information!