This is the story of how a few raw steel tubes, some bicycle parts, and a bit of stubbornness turned into this scooter. No internet blueprints, no ready-made kits — just an idea in my head and hours of work in the workshop.

Phase 1: The Idea and the Sketch

It all started with a simple question: “What if I built a scooter made mostly of bicycle parts, with an electric motor, that could handle rough terrain?”

Concept sketch / First notes

I didn’t have a ready-made plan. I started with sketches on paper — wheelbase, battery placement, head tube angle. I knew I wanted:

  • Large wheels — better stability than standard scooters
  • Front suspension fork — comfort on uneven ground
  • Central battery placement — low center of gravity
  • Rear wheel drive — classic construction

Phase 2: Materials and Parts

Before I started cutting metal, I had to gather everything I needed:

Component Source Notes
Steel frame Tube bent to order Main frame
Suspension fork Old dirt bike Large, 150mm travel
26" and 24" wheels Mountain bikes Front and rear
Hub motor (250-500W) AliExpress MXUS Drive
Li-ion battery AliExpress Mounted on frame, 48V
Controller and throttle Included with motor Electronics
Standing platform Laser-cut and welded Custom design

Frame Set of water-jet cut parts

Phase 3: The Frame — The Key to the Scooter

This was the most difficult stage. The frame had to be stiff yet light. I made it from S355 steel tube welded with TIG.

Step by step:

  1. Measurement and cutting — precise tube bending according to a 3D model at a specialized company
  2. Edge grinding — preparation for welding
  3. Welding in a jig — ensuring symmetry and correct angles
  4. Finishing work — grinding and cleaning the welds

Bent tube Welding reinforcements Rear triangle Welding the platform

💡 Tip: Thin steel is demanding to weld. Clean edges and the right parameters are the key to a durable weld.

Phase 4: Suspension and Wheel Assembly

Once the frame was ready, it was time for the remaining details. A test assembly with the wheels before further stages. A quick check to see if I was on the right track.

Wheels on the frame

Wheelbase and geometry were critical. Too steep a head angle = twitchy handling. Too slack = sluggish turns. After minor corrections, I hit the sweet spot.

Phase 5: Electrics — The Soul of the Project

Without the electrics, it’s just an ordinary scooter. I installed:

  • Rear hub motor — maintenance-free, quiet
  • 48V / 10Ah battery — mounted centrally on the frame
  • Controller — hidden under the platform
  • Throttle grip — on the handlebar
  • LCD display — speed and charge level

Test ride!

First ride

Then came the time for smaller and larger details, like the battery mount.

Battery mount

Phase 6: Finishing and Details

Raw steel looks cool, but it rusts quickly, so painting was essential: Eventually I plan to powder-coat the frame, but for this first prototype I sprayed it in the backyard :)

Painting

The scooter after assembly with the controller visible.

Controller

Phase 7: The First Ride

The moment of truth. Tension, turning the key, a gentle twist of the throttle… and we’re off!

Citadel

The scooter after the first 1,000 km. The weirdest vehicle in the rack! Bike rack

Time for the nameplate! TAWA was 3D-printed and fitted to the curve of the frame. TAWA 3D-printed nameplate

The nameplate on the side of the frame fits the yellow beast perfectly! TAWA on the frame

First riding impressions? Surprisingly stable. The large wheels do the job, and the central battery keeps the center of gravity in a good spot. Acceleration is smooth, and the range is enough for daily commutes — about 50 km.

Technical Specifications

Parameter Value
Frame S355 steel, TIG welded
Wheels 26 and 24 inches (MTB)
Suspension Front fork
Motor Hub motor 250-500W MXUS
Battery 48V / 10Ah (360Wh)
Range ~50 km (depending on mode)
Max speed 40-45 km/h
Weight ~22 kg
Brakes Disc (rear only for now)

What Would I Change?

Every project teaches you something new. If I were to build it again:

  1. Lighter battery — I’d consider lighter, higher-quality cells
  2. Disc brakes — I’d add a front brake; rear only is not enough
  3. LED lighting — factory-integrated with the battery

Summary

This was a months-long adventure full of challenges, mistakes, and small victories. The result? A scooter that no one else has. You can’t buy it in a store. There’s no other like it.

“Hand-built things have a soul. I left mine in every welded joint.”

Have questions about the build? I’d be happy to share details if you reach out 👇 info@borilab.pl