I recently had the opportunity to visit the Katanga cycle factory in Brno, Czechoslovakia. They manufacture various types of recumbent cycles, including my favourite cargo bike, the PONY4. It may seem like a very simple design, but appearances can be deceiving. The PONY4 is a well-thought-out design that ingeniously combines light weight with a large cargo capacity and suspension on all four wheels. The seating position is the same as on recumbent bikes, which makes cycling very comfortable. The seat used instead of a saddle also makes it possible for people with certain mobility disabilities to cycle with a large load. This bike is available in many different variants, but above all it is used as a basis for those who want to adapt the cargo bike to different purposes.
Before the actual assembly of a PONY4 is done, many parts have been prefabricated, and the actual assembly takes a day and a half of work. Here you can see in detail how Josef ”Pepa” Londa puts together a PONY4 long frame with a simple cargo platform.
I would like to thank the Katanga factory for letting me follow the assemblage and document it with the camera in my mobile phone.
Image on top: Josef Londa, called Pepa with the PONY4 that you are about to see being built.
My own PONY4 with a simple trailer which I built myself. The trailer can take up to about 250 kg cargo. If there is sunlight, the solar panels I installed make it possible to cycle 80 to 100 km daily without charging the battery through a wall outlet.My PONY4 loaded with lumber.My PONY4 with a foldable tent mounted on the trailer.The tent on my PONY4 trailer unfolds in a couple of minutes.
A PONY4 is Born
The frame arrives fully welded and painted at the factory where the bike is assembled.The parts that will be included in each PONY4 are chosen by the customers. Here Pepa marks what will be included in this particular PONY4.The frame number is stamped.The frame is screwed onto a jig.The front suspension is mounted.The frame is turned around on the jig and the rear suspension and strut to the loading platform are screwed on.The rear axle is centred and screwed on.The rear suspension is tightened with 40 Nm of torque.Front brake drums from Sturmey Archer are mounted at the same time as a strut for the mudguard.High-quality drum brakes require minimal maintenance and are very reliable.The front wheels are put in place.The rear axle is lubricated and covered with a protector to prevent rust.The rear wheel bearings lock for propulsion but not in the opposite direction. This allows the rear wheels to rotate at different speeds when cornering.The rear wheels are mounted after the bearings have been lubricated with oil. It is important that the right and left wheels are mounted on the correct side.The upper stainless-steel rails are put in place but not tightened yet.Parts of the steering are put in place.It is important that everything is screwed on at the correct angle.After fine adjustment, it is time to tighten the screws.A bracket for the seat has been put in place.To align the front wheels, all wheels are clamped with two parallel aluminum rails.A square ensures centering of the steering, and it becomes possible to adjust the steering rods.The angle of the front wheels is adjusted with a special tool. On a PONY4 with a long frame, the front part of the front wheels should be angled two millimetres out (Toe out 2 mm). On a PONY4 with a short frame, the front part of the front wheel should be angled two millimetres in (Toe in 2mm).The handlebars are measured and put in place.The brake levers and brake cables are installed.On most PONY4s, the Rohloff gear is used, which is considered one of the two best gears in the world. These gears cost more to purchase than a regular box-bike costs to buy in Sweden.The Rohloff and rear chain tensioner are installed.The rear chain sprocket is clamped onto the axle.The rear chain tensioner is installed.Here too, the screws are tightened with 40 Nm of torque.The length of the boom is adjusted to the customer’s height.The well-proven mid-motor comes from Bafang.The front chain tensioner is installed.The chain tubes are heated and shaped so that they do not catch on the chain.The gear lever is installed.In this case, the customer has only ordered front mudguards. At the back, the customer will build a large box for her dogs.The speed sensor is installed.Springs on the shock absorbers are adjusted to the weight of the estimated load.Rear shock absorbers and suspension are adjusted depending on the needs.Additional struts for the cargo bed are mounted. There are many different alternatives for this and they are determined according to the customer’s wishes.Battery holder is mounted on the simple cargo bed.Cables are pulled from the motor and display on the handlebars.Almost done, only a few small details left.Pepa has taught me a lot during the work that took a day and a half. Now I understand better why a high-quality cargo bike also has its price!The very first meters cycled with the PONY4 that we just built together with Pepa at the Katanga factory.Manager Samuel Thál and Josef “Pepa” Londa with the newly manufactured PONY4 in front of the Katanga factory.
