Power Porter Wheel unit deep dive (missing images and needs prod dev final check)

A question we are often asked at shows, and one we’re more than happy to answer. While the frame designs of barrows may appear similar—wheels, handlebars, and a load space—the difference lies in the power kit. In this article, we’ll focus specifically on the design of our wheel unit and what sets it apart from the competition.

When it comes to power, our barrows stand out as the most powerful on the market. This is achieved through several design choices, starting with the motor. We use Parvalux 24v externally mounted motors, a company that has been in the motor business since 1947. Their expertise is reflected in the over-engineered design of the motor, which is built to last far longer and work harder than the typical motor you might find in other barrows. These motors are built for durability and reliability, meaning you can trust your barrow to deliver power when you need it.

The Parvalux motor runs through a gearbox mounted just below, which serves two key functions. First, it changes the orientation of the output from vertical to horizontal, allowing the wheel to turn. Second, the gearbox has a 30:1 ratio, meaning every 30 revolutions of the motor turns the axle once. This setup has two main benefits:

This higher torque and slower wheel speed mean that our barrows can handle heavy loads with ease. Additionally, reversing the polarity of the motor provides a reverse gear, giving you full control when manoeuvring the barrow.

The torque from the motor is transferred to the drive shaft, which is permanently fixed into the unit. To ensure smooth turning, we use two lifetime-sealed bearings on either side of the shaft, while the axle components are CNC-machined locally in the UK. Not just the drive shafts, but the axle assemblies, supporting bars, motors, and gearboxes are all supplied by UK-based firms. This focus on UK craftsmanship ensures high-quality components that work seamlessly together.

Our barrows are designed with a fixed axle that remains “in gear” and doesn’t freewheel. However, we incorporate a ‘Dog Clutch’ system—a design used in race cars—that allows you to disengage the drive train with a simple pull and twist of the collar on the axle. This feature means you can run the barrow on its two bearings when needed, without the strain of the drive mechanism. The Dog Clutch is highly durable, and its minimal wear ensures long-lasting performance, unlike manual transmission clutches that suffer from constant friction

The wheel setup is crucial to ensuring the power is effectively transferred to the ground. We use a tubeless tyre system, where the tyre is sealed directly against the hub, similar to a car tyre rather than a traditional bicycle tyre. This setup offers several benefits:

The tyres are big, heavy-duty, and chunky, providing excellent traction. Since all the driving force goes through the front wheel, a proper tyre design ensures that all the power is transferred effectively, minimising wheel spin and maximising traction.

We’ve completely re-engineered the Power Porter’s electronic control system for 2025, working with a top UK electronics firm to deliver major improvements in reliability, performance, and ease of use. The new drive control unit (the black box beneath the battery tray) features modern circuitry that’s better sealed, more robust, and now runs near-silent thanks to a 20kHz operating frequency.

Standout features include soft-start and soft-stop for smooth operation, an instant stop safety function for tight manoeuvres, an adjustable speed dial with built-in reverse gear, and quick-release connectors for easy pack-down. Whether you’re navigating rough banks or storing the barrow between sessions, these updates make a real difference on and off the bank. For more information [follow this link]

One of the key aspects that make our Power Porters unique is how much we source and produce in the UK. As mentioned earlier, the drive components, including shafts, axles, and motors, are all CNC-machined locally. The entire electronics system has also been reworked with a UK-based company, allowing us to have full control over the quality and design.

This commitment to UK manufacturing is not only a point of pride but also ensures that, should anything go wrong, we can provide quick and efficient repairs in-house. We have all the necessary tools to diagnose, repair, and rebuild your Power Porter on-site. Plus, we offer rebuilds as a service for those who want the peace of mind that comes with having our technicians maintain and inspect their barrows.

In summary, our Power Porters stand out due to their advanced motor design, high-quality UK-made components, and unique features like the Dog Clutch and tubeless tyres. The combination of these elements gives our barrows unmatched power, control, and durability. When you choose one of our Power Porters, you’re not just getting a barrow—you’re getting a product crafted with care, precision, and a deep commitment to quality. And, with our in-house service and support, you can be sure that we stand by our product every step of the way.