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Extreme Power Porter Assembly Guide: Big Performance, Simple Setup

The Extreme Power Porter may be our largest and most feature-packed model, but don’t let its size fool you — assembly is straightforward and user-friendly. This guide will walk you through the process step by step, ensuring you’re fully set up and ready to roll with confidence.

Step 1: Rear Wheel Assembly

Start by assembling the rear wheels:

Take the axle shaft and slide it through the axle assembly.
Fit one large washer onto the axle, followed by the wheel.
Add another large washer, then a small washer onto the thumbscrew thread.
Tighten the thumbscrew securely.

Repeat this process for the second wheel, and your rear wheels are ready to fit.

Step 2: Front Wheel Assembly

The front wheel unit is fully assembled from the factory. All you need to do is attach it to the frame.

Flip the barrow frame onto its back, with the fork lugs facing upward.
Ensure the thumbscrews on the front wheel forks are undone.
Carefully slide the wheel unit down the forks, ensuring it seats fully — a light jiggle can help it settle into place.
Check orientation: the two 10mm bolts and washers should face the front of the barrow.
Tighten the two short T-screws on the sides of the fork.
Locate the two long T-screws and fit them to the rear of the fork assembly.

Note: Ensure all four screws are tight enough to hold the wheel securely, but don’t overtighten — excessive force can deform the metal lugs.

Check the bolts near the front crossbar to ensure they’re secure.

Step 3: Attaching Rear Legs and Wheels

The rear legs come pre-installed to help with barrow tracking, so all you need to do is fit the rear wheel axles:

With pre-drilled holes facing rearward, pull out the locking pin on each leg.
Slide the assembled axle and wheel into the leg.
Choose your desired height and release the locking pin to secure it.

Once both are fitted:

Turn the barrow onto its wheels.
If happy with the height, fit the thumbscrews on the opposite side of the leg to lock everything in place and prevent wobble.

Step 4: Handle Assembly

You’ll need a Phillips screwdriver and 8mm spanner.

Identify the two L-shaped handle arms. The hole on the long edge is where the lower folding handles attach.
Align the lower handle bracket with the hole at the bottom of the L-arm.
Push an M5 bolt through both pieces and secure using the nyloc nut.
Tighten with screwdriver and spanner until the thread bites the nylon — do not overtighten, as this may prevent the handles from folding.

Now:

Slide the handles into the rear of the barrow frame.
Loosely secure using the thumbscrews.
Slide the handlebar down the L-shaped arms and tighten its thumbscrews.
Go back and tighten the previously loosened screws to complete the setup.

Step 5: Frame Assembly

Insert the side bars and tighten the underside thumbscrews.
Fit the support bar onto the angled uprights, then slide the full assembly into the front of the frame.
Insert the front bar into the angle adapters and secure with thumbscrews.
Fit the rear brake into the empty frame tube between the handles and tighten with thumbscrews.

Test the brake: It should make friction contact with the tyre tread. While effective, this system relies on pressure, so take care when parking on steep banks.

Step 6: Connecting the Electronics

Now to plug everything in.

Ensure the hand controller is off by turning the speed dial fully anti-clockwise.
Locate the wheel-to-frame connector near the front wheel.
Align the white arrows on both connectors and press them together.
The winged collar will twist and click into place. Important: Misaligned connectors can cause pin damage — this is not covered under warranty.
Repeat the process for the handlebars-to-frame connector.

Place the battery onto the tray.
Locate the black and orange connector for the battery-to-wheel unit.
Match black to black, orange to orange, and push the connectors together.
The alternating sides will guide the alignment.

Ready to Hit the Bank

With everything assembled and connected, your Extreme Power Porter is now ready to go. Just charge your batteries, double-check all fasteners, and you’re good for your first trip.

Need further support or assistance with setup?
Our team is here to help — reach out to our customer support team or explore more assembly and operation videos on our support hub.