Foot brake conversion

Stock RCR braking is two levers: right for the front, left for the rear. The left lever also triggers regen, and regen is binary, meaning on or off. A foot pedal frees a hand, and a sensor on the pedal can make regen progressive. This article follows one build as a worked example.

Why the stock setup is a constraint

• The rear caliper is cable-pulled, so a pedal needs either a cable pull or a separate hydraulic system.
• The left lever has a brake light switch that also tells the controller to start regen. A stuck or shorted switch cuts the throttle, so any new sensor wiring needs care.

The design

• The stock crankshaft is replaced with a 16 mm solid axle through the bottom bracket shell. The footpeg kit mounts to this axle.
• A small adapter plate slides onto the axle and is held by the existing hex nut. A tab against the face of the shell stops it rotating.
• The plate carries a Surron-style foot brake kit with its master cylinder, so braking stays hydraulic.
• An AS5600 magnetic angle sensor reads the pedal pivot and sends a progressive regen signal to the controller. That only works with a controller that accepts an analog regen input; see Variable regen for the requirements and the battery limits.

Build notes

• The axle projects roughly 40 to 50 mm past the shell on each side.
• Prototype the plate in acrylic before cutting aluminum.
• Test the pedal, line routing, and regen at a standstill, then at walking pace, before any road riding.
• Under the manual’s warranty terms, unauthorized modification and non-standard parts void the warranty.

CONFIRM: Alexander: kit bolt pattern, nut thread and across-flats, controller regen input voltage, final photos and plate drawing