I visited Ride1Up’s e-bike factory to find the secret behind good quality, low-cost e-bikes
I’ve been riding Ride1Up e-bikes since just about their first model. Over the many years since I first threw a leg over that bike, I’ve watched the company roll out an ever-increasing lineup of diverse e-bikes that all shared one common trend: great bang for your buck.
So when I was recently touring Asia to visit micromobility factories for a peek behind the curtain, I knew Ride1Up’s factory would be high on my list. They invited me out to join the company’s founder, Kevin Dugger, on a tour of the factory so I could see just how Ride1Up goes about ensuring they can keep the quality high and the prices low.
Like nearly every other e-bike company in the US, their bikes are produced in China. But you can get a wide range of quality across such a large country with vast manufacturing facilities. If you cheap out, you get cheap products. But if you design a production system with triple and quadruple quality-assurance inspections, you get well-made products that treat their owners right for years to come.
That’s the calculation Ride1Up made, and it’s paying dividends for the company in reducing customer issues and thus, customer complaints. And when you have as generous of a return policy as Ride1Up, you darn well better make sure people get their bikes in good shape and that those bikes last as long as riders expect them to.
My tour of Ride1Up’s factory took me straight onto the factory floor where parallel production lines were busy cranking out Ride1Up’s ultra-affordable $995 Portola folding e-bike on one side of the factory, and the company’s budget-priced $2,295 CF Racer1 carbon fiber road/gravel e-bike. And yes, when it comes to carbon fiber road and gravel e-bikes, 2 g’s is crazy low-priced.
To see a tour of the factory and learn the secrets behind making high-quality e-bikes, check out my video below. And don’t forget to keep reading below for even more detail!
Before parts get to either of those lines though, they first go through pre-check. Wheels are built up around motors and front hubs using automated lacing machines that then feed into automated checking robots to ensure they’re properly laced and tensioned.
Any wheel that doesn’t come out exactly right is shunted off to a side chute where a human inspector can evaluate it and send it back for reworking until it’s perfect.
The process combines both manual and automated tasks, drawing from the best of both types of resources.
Frames are inspected at this point too, having been sent in from another off-site welding and painting building (as Ride1Up’s factory is located in a lower-emissions area).
The frames are inspected for any paint knicks or imperfections, and any frames with issues are marked for repair before being sent off for assembly.
The rest of the frames move on to the assembly line.
Those pre-inspected frames are hoisted off to the initial assembly area by an elevated conveyor, where initial assembly will begin.
On the other side of the conveyer, a worker receives the frame and sets it up at its first station so that lights can be installed on the rear rack and internally run cables can be passed through the frame tubes.
Controllers are then installed into the frames, but only after being scanned into an intelligent management system that digitally pairs each component with the bike frame. This is used for accountability in the future. If a component is ever found to be defective, such as if a controller manufacturer reports back that a certain batch of 20 controllers has an issue, Ride1Up can instantly know which bikes may be affected and can trace that exact bike and controller to its owner, even months or years later.
For the Portola folding e-bikes, the frames are then ready to be loaded on the assembly line’s conveyor system, which slowly moves down the line to each worker’s station.
The first step is to install the pedal drivetrain, which includes the bottom bracket, chainring, cranks, and pedals. Next the folding hardware is installed, followed by the kickstand and the rear wheel with the motor. Each component is held on using specially treated hardware designed for corrosion resistance, with bolts having thread locker compound applied to ensure they don’t shake loose.
The handlebars are then mounted to the frames along with the front fork. With the handlebars mounted, the wiring, shifter cable, and brake hoses can all be routed up to the bars. Wire wraps are applied to make the wiring hardness look neat and tidy, and then a battery is installed. Just like the controller, major parts like the motor and battery are also scanned and recorded so that documentation exists for each e-bike to maintain a record of its entire parts list.
The tools used in each step are also regularly calibrated using sophisticated electronic tools, ensuring that if a bolt requires 10 Nm of torque to be applied, the torque wrench is truly outputting 10 Nm of torque.
Reaching the end of the automated conveyor system, the e-bikes are flipped onto their wheels and rolled over to a finishing station, where another worker indexes the shifter, calibrating it so that all of the gears shift crisply and without jumping.
On this day, the parallel line was assembling the carbon fiber CF Racer1 e-bike. Only the most experienced workers are put on this assembly line due to the higher tolerances of carbon fiber bike work. There also aren’t any power tools used on this line; all of the assembly steps are performed using precision hand tools to avoid applying too much stress to the carbon fiber frame.
The general steps are similar to those seen on the first assembly line, but performed with an even higher level of sophistication. Frames are first visually inspected to weed out any imperfections before being hoisted along a hanging conveyor system to the assembly line. From there, workers install the controllers, batteries, wheels, handlebars, shifter, pedal drivetrain, and any other hardware.
After reaching the end of the assembly line, the bikes are rolled off to their own finishing area, where the brake lines are bled and the shifter is calibrated.
Once fully-assembled, both bike models are rolled off into their own corrals, where they await visual inspection. Quality testers go over the bike to inspect dozens of points and ensure they are assembled correctly.
Any issues are marked and the bikes are rolled off into a side corral for remediation. The intelligent tracking system also correlates the issue to the worker who performed that task, allowing the factory to root out systematic issues by immediately addressing any mistakes that a worker might make. Workers with few or no mistakes also get monetary bonuses to their salary, providing further incentive for the bikes to be assembled perfectly the first time.
The approved bikes are then passed onto the next stage of ride testing.
At this point, none of the e-bikes have any saddles. That’s because they’re all ride-tested to ensure all functions are working properly, and these workers use the same seats that are switched from bike to bike. The actual saddle that ships with the e-bike is added just before packaging, ensuring that when a customer eventually opens their e-bike, theirs are the first cheeks to grace that saddle.
Once the bikes pass their ride testing, they are considered complete, though they aren’t yet ready for packaging.
Before the e-bikes can be packed up, they first must go through a series of third-party inspections. These outside contracted inspectors aren’t Ride1Up’s factory employees, but actually work somewhat antagonistically with them. Their job is to redo all of the inspections and find anything that was missed in the several previous rounds of inspections.
Because they are technically not Ride1Up’s factory employees and instead come from an outside inspection agency, they approach the inspections differently and are better positioned to find any issues that could have slipped through the previous several rounds of in-house inspections.
Only once the e-bikes pass third-party inspections are they considered ready for boxing up. At that point, they head to the last conveyor belt of their journey, which sends them along a packaging routine that has been meticulously refined by Ride1Up over several years. The company has applied the experience of shipping tens of thousands of e-bikes to find ways to best protect the bikes while also minimizing the amount of plastic and foam used in the process.
As I looked through the packaging steps, I couldn’t find any foam traditionally used in bicycle packaging, and the only plastic I saw were the cable ties and a single piece of soft plastic used to protect the fork.
Interestingly, there was still one final inspection point applied even after boxing up the e-bikes. The entire box is precision weighed, which ensures it comes out to the exact right weight.
If a single component or piece of packaging was forgotten, the box would be too light and the factory would know there was an issue.
It’s just the cherry on top of an entire system full of redundant safety and quality inspections performed before, during, and after the assembly process.
I’ve seen a lot of e-bike factories in my years covering the industry, but it’s rare to see this many spot checks and quality assurances built into so many different areas of the production and assembly process.
The tour was a fascinating look behind the curtain of how Ride1Up builds its e-bikes, and helps answer the question of how they can offer so much value.
As a direct-to-consumer company, they have to offer e-bikes that work well right out of the box. These e-bikes are being shipped largely to private customers, not bike shops and professional assemblers. So they have to be ready to roll, without the need for repairs, right from day one. Anything else would result in a costly return process for Ride1Up.
Over the years, they have refined their system for building quality e-bikes that are built to last while still offering a reasonable price point for riders.
I’ve long touted the company’s quality and performance from my own testing of their various e-bike models. But that was always merely the end of the story – riding the finished product. Now, having seen the assembly and quality inspections firsthand, I can finally vouch for their professionalism from the very start of the process.
FTC: We use income earning auto affiliate links. More.
America’s heartland is full of rural communities that are miles away from its major cities, both geographically and culturally – but that doesn’t mean these more sparsely populated regions can’t reap the benefits of electrification. In fact, EVs offer rural drivers even more benefits than they do to city-dwellers!
“An electric lifestyle would be a boon to our rural heartland,” wrote the Union of Concerned Scientists’ Maria Cecilia Pinto de Moura. “Rural communities across the country have their own distinguishing characteristics, but certain shared characteristics such as driving distances, the type of vehicles driven, and socio-economics are factors which contribute to this larger potential to benefit from vehicle electrification.”
Pinto de Moura went on to outline five ways rural and country drivers could benefit from going electric – but that was in 2021, and a whole lot has changed in the nearly five years since.
As such, I thought it was high time we revisit some of the reasons EVs could be a great fit for rural lifestyles, see if we could uncover any new ones, and outline the reasons we think rural drivers should rush to embrace electric vehicles in the coming calendar year.
1. More miles means more savings
When you hear that line about, “the average American drives 30 to 40 miles a day,” remember that in towns like Wellington, Ohio, or Colfax, Washington, 30 miles is a grocery run. Each way. So when people trot out that old line about range anxiety, what rural drivers actually hear isn’t reassurance. It’s dismissal — a suggestion that they drive too far for an EV to work, when nothing could be further from the truth.
A recent study by Rural Climate Partnership found that rural drivers spend an average of 44% more on fuel than city dwellers, and that the top 3.6% of rural drivers — the “supermilers” who rack up the most miles — could save over $4,000 each year by switching to electric fuel.
2. Electric trucks have arrived
Country guys and gals love their pickups, and arguably the single biggest difference between the EV markets of 2021 and 2025 is the proliferation of electric trucks and SUVs ready to help haul, chore, camp, and tow.
Why not save your expensive horses from breathing in gas and diesel exhaust. Haul ’em with your quiet new EV, instead!
3. Home charging just works
With only about 45% of rural counties having access to DC fast charging, public charging still isn’t as visible as many first-time EV buyers might like, but it’s far better than it used to be — and improving fast. Still, that’s not the real EV advantage. Home charging is.
Unlike many apartment-dwelling urban drivers, most rural owners can charge right at home. More than 80% of rural households have a driveway or garage that are ideal for overnight Level 2 charging, and many already have a 240V outlet, keeping setup costs (if there even are any) to a minimum.
Plug in before bed, wake up to a full battery every morning, and do it for pennies on the dollar, especially with off-peak rates.
4. Lifesaving battery power
If disaster strikes and you lose power, many electric trucks have the ability to power your home and appliances with the energy stored in their massive batteries – either from the truck itself, or through a V2X home battery system. If you live in an area prone to extreme weather events, the ability to keep medication refrigerated can be a literal life-saver!
5. EVs are more affordable than ever
It’s been a few years since a working class guy could reasonably expect to get a new pickup for less than $50,000. And, while much has been made of the “high cost of electric vehicles,” the truth is that thanks to killer lease deals, new tax incentives, and companies like Ford Pro and TRC that are willing to help you find even more funding to help pay for them, EVs can often be had for less than a comparable gas model.
As such, getting behind the wheel of an ultra-powerful, ultra smooth-running electric pickup truck from your favorite brand is easier than ever.
6. Energy independence and American jobs
At the risk of sounding like a paranoid red hat, rural Americans are proud Americans – just like rural Canadians are proud Canadians. Unfortunately, every gallon of gas burned in their pickups and SUVs came from oil drilled, refined, and traded on global markets — and that means supporting the oil business and economies of nations whose values don’t always align with, or maybe are even outright hostile to theirs.
Switching to an EV can help more of that money right here at home, especially as more and better battery recycling efforts come online and newer battery and anode/cathode chemistries are developed, reducing dependence on rare Earth metals, cobalt, and even lithium.
Even better, thanks to the rapid expansion and dramatically reduced costs of wind and solar power, you can power your EV with energy that is 100% Made in the USA, that doesn’t support foreign oil interests even indirectly, and which creates good-paying construction and maintenance jobs for local workers.
What am I missing?
There are obviously more reasons to go electric than these, from lower cost of ownership to saving the planet to absolutely killer burnouts that would make the one-tire-fire era IROC Camaros hang their 305s in shame – but I think those kind of fade into the background as being appealing to all, instead of being especially appealing to rural drivers.
That said, it’s been a long time since I was back in Ohio, so maybe I’ve forgotten what it’s like. You guys are smart, head on down to the comments and let me know what I missed!
Original content from Electrek.
If you’re considering going solar, it’s always a good idea to get quotes from a few installers. To make sure you find a trusted, reliable solar installer near you that offers competitive pricing, check out EnergySage, a free service that makes it easy for you to go solar. It has hundreds of pre-vetted solar installers competing for your business, ensuring you get high-quality solutions and save 20-30% compared to going it alone. Plus, it’s free to use, and you won’t get sales calls until you select an installer and share your phone number with them.
Your personalized solar quotes are easy to compare online and you’ll get access to unbiased Energy Advisors to help you every step of the way. Get started here.
FTC: We use income earning auto affiliate links. More.
Honda’s electric SUV is on a roll. The Prologue was the third best-selling EV in the US in August, trailing only the Tesla Model Y and Model 3. Even with the federal EV tax credit now expired, Honda is still offering nearly $17,000 off the Prologue.
Honda Prologue registrations surge with huge incentives
As the $7,500 credit expired at the end of September, automakers rolled out steep discounts, many topping five figures with combined incentives.
The Honda Prologue has been one of the most discounted EVs over the past year or so. Last month, buyers could score up to over $20,000 in combined savings, including a $7,500 credit, $9,500 in financing bonuses, trade-in offers, and 0% interest for six years.
According to the latest registration data from S&P Global Mobility (via Automotive News), the incentives helped propel the Honda Prologue to become the third most popular EV in August.
A total of 138,457 EVs were registered in the US in August, up 24% from a year ago. Honda Prologue registrations surged 81% to 9,005 vehicles, the data showed.
Honda’s electric SUV had more registrations than the Chevy Equinox EV in August, and it’s based on the same GM Ultium platform. However, the Equinox is still outselling the Prologue through September.
Since some automakers don’t report monthly or US sales numbers, the S&P Global Mobility data offers a snapshot of sales performance.
The Prologue was yet again one of the most discounted models, with incentives of $12,704 in August, according to Motor Intelligence. Last August, Prologue incentives were just $5,813. Honda’s gas-powered CR-V had just $2,016 in incentives in August.
Although the $7,500 credit expired on September 30, Honda is still offering generous incentives for Prologue buyers and lessees.
The 2025 Honda Prologue is available with up to $16,550 in lease cash in most states. The offer includes $5,000 in lease bonus cash, $8,250 in Honda lease cash, and a $3,3300 loyalty or conquest bonus. Honda is offering the deal until November 11. Or, you can opt for 0% APR financing for up to 60 months.
2025 Honda Prologue trim |
Starting Price* | EPA Range (miles) |
| EX (FWD) | $47,400 | 308 |
| EX (AWD) | $50,400 | 294 |
| Touring (FWD) | $51.700 | 308 |
| Touring (AWD) | $54,700 | 294 |
| Elite (AWD) | $57,900 | 283 |
Although the Acura ZDX will not return for a 2026 model year, Honda is planning to launch the 2026 Prologue. We have yet to learn prices, but we could see it priced slightly lower due to the loss of the $7,500 EV credit.
Hyundai announced earlier this month it’s reducing 2026 IONIQ 5 prices by up to nearly $10,000 on some trims. The 2026 Hyundai IONIQ 5 now starts at under $35,000. Hyundai is offering leases as low as $289 per month right now. Will Honda match it?
Want to see the Prologue in person? You can use our link to find Honda Prologue models near you (trusted affiliate link).
FTC: We use income earning auto affiliate links. More.
Kia has a new idea. So you don’t miss the smell of gasoline too much when you trade in for its new EV, Kia is giving away free gas-scented air fresheners.
Kia offers gas-scented car fresheners for EV4 buyers
It’s time to trade that new car scented tree dangling from your rearview mirror for a jerry can that smells like… gasoline?
Astara Auto Finland, which imports Kia’s vehicles into Finland, is giving away free gasoline-scented car fresheners for those buying the new EV4.
Although it may seem like Kia’s poking fun at the gas guzzlers, it’s actually partly designed to ease your transition to an EV.
“Giving up the combustion engine can feel like a huge step, just like giving up anything else that is familiar. We wanted to add a touch of nostalgic fun to the transition with a gas-scented car freshener,” Klaus Pohjala, commercial director at Astara Auto Finland, said.
The scent was created by Finland’s sole perfumier, Max Perttula, who has developed fragrances for other premium brands.
According to Pertulla, he mostly used scents found in men’s fragrances, but added a bit of Jasmine to top things off. “It may sound wild that it’s jasmine of all things that contains compounds with a fragrance that creates associations with gasoline,” Pertulla said, but it works.
The fragrance came to life after metalizing and sanding it with amber compounds, birch tar, and galbanum, he explained.
Of course, it’s a bit of a “cheeky campaign,” Pertulla said, but Kia aims to add a little fun for new EV drivers. The latest campaign comes after Kia’s importer ran a controversial front-page ad last year mocking traditional luxury automakers, claiming EVs have leveled the playing field.
The EV4 is rolling out in Europe, in both hatchback and sedan variants. Early next year, Kia will launch the sedan version in the US.
Do you miss the smell of gas? After driving an EV for years, I still think that it’s one of the best parts of owning one. Drop us a comment below and let us know what you think.
FTC: We use income earning auto affiliate links. More.
-
Sports3 years ago‘Storybook stuff’: Inside the night Bryce Harper sent the Phillies to the World Series
-
Sports2 years agoStory injured on diving stop, exits Red Sox game
-
Sports2 years agoGame 1 of WS least-watched in recorded history
-
Sports3 years agoButton battles heat exhaustion in NASCAR debut
-
Sports3 years agoMLB Rank 2023: Ranking baseball’s top 100 players
-
Sports4 years ago
Team Europe easily wins 4th straight Laver Cup
-
Environment2 years agoJapan and South Korea have a lot at stake in a free and open South China Sea
-
Environment1 year agoHere are the best electric bikes you can buy at every price level in October 2024