MF-01 — Custom neo-vintage electric bike

12 de febrero de 2026 por

Federico Solutions, Myrko Federico

MF-01 — Custom neo-vintage electric bike (Switzerland)

Sector: Prototyping / Electric Mobility / Industrial Design Period: 2013-2014 (design and prototyping) Status: Unique prototype — personal use

Context

In 2013, I designed and built from scratch acustom neo-vintage electric bike, inspired by the early Harley-Davidsons — the idea of a motorcycle that was originally a bicycle, reinterpreted in the modern era.

Vision:An object at the intersection of vintage bicycles, high-end mechanical watchmaking, and electric vehicles. The transmission and the gear reductionapparent and visible, like the movement of a watch — art in motion.

Swiss legal framework:

Light moped (art. 18, OETV)
Max motor 500W
Max pedal assistance 25 km/h
Manufacturer speed limited to 20 km/h (actual speed 82.5 km/h)
No type approval required

Problem

Design challenge:

Start from a custom "beach cruiser" frame not intended for electric motorization
Integrate a complete electrical system (motor, battery, electronics) in a way that isaesthetically coherentwith the vintage style
Make thetransmission visible and aesthetic(apparent gear reduction — the DNA of the project)
Comply with the Swiss legal framework while maximizing performance

Mechanical challenge:

Frame not suitable for many standard components: need tomanufacture custom parts
Adaptation of the braking system (front/rear discs on a frame not prepared for discs)
Integration of the GNG 48V motor into the frame without a designated mounting point
US/EU bottom bracket compatibility (BSA → OPC conversion)

Electronic challenge:

Design of the PAS (Pedal Assist System) <25 km/h
Integration of throttle >20 km/h with option to disable the limiter
Custom electronic housing to accommodate 48V/15Ah battery + controller
OLED display with dedicated CNC housing

Constrained budget:

Total budget: CHF 2,980.
Optimization of supply sources (4 countries: Germany, Hong Kong, France, Switzerland)

Solution

Homemade parts (60h prototyping + 80h component research)

All connecting and adapting parts have beendesigned in CAD and manufactured in the workshop :

Mechanical:

Brake disc spacers front and rear (caliper adaptation)
Front wheel axle bushings (fork adaptation)
Welded motor mount on frame
Motor chassis made with plasma and bolted
Welded battery box support on frame
Shortening of the steam and fork tube
Fork tube caps

Electronics / Interface:

Battery box (housing 48V/15Ah + controller + wiring)
CNC machined OLED display mount
Front headlight mount
Complete electrical diagram (PAS + throttle + limiter option)

Battery case — Custom sheet metal

Complete design and manufacturing:

CAD design of the case (constraints: integrate into the frame, accommodate 48V/15Ah battery + controller + wiring)
Sheet metal work done in-house: cutting, bending, assembly
Welded mount on frame (homemade support)
Finish: black paint, engraved MF logo
Result:custom case perfectly integrated into the bike's silhouette — the transmission and electronics becomepart of the design

Control system — Complete Arduino development

Bike brain developed from scratch:

Hardware:

MicrocontrollerArduino
ScreenNokia 3210(communicationI2C)
CNC machined speedometer case (aluminum)
Sensors: speed, pedaling (PAS), temperature

Developed logic:

PAS (Pedal Assist System): pedaling detection + proportional motor activation
Speed limiter: assistance cut-off at 25 km/h (Swiss legal) with option to disable
Throttle: direct motor activation >20 km/h
Multifunction display :
- Instantaneous speed (km/h)
- Odometer
- Battery autonomy
- Display on Nokia 3210 screen

Meter housing:

Complete 3D drawing
CNC machined from solid (aluminum)
Handlebar integration
Anodized finish for aesthetic consistency

Electronic development time:included in the ~140 total hours (60h prototyping + 80h research)

Finishes:

Sanding frame and parts
Anodizing of home-made parts
Rear wheel lacing (Shimano Alfine 8-speed)

Key components

Motorization:

GNG 48V 450W motor (visible central transmission)
VK Power 48V 15Ah battery
Chain transmission with visible reduction

Frame & Geometry:

Custom Frame Royal (high-quality steel, beach cruiser style)
Extra Wide Double Crown 660 Black Fork
SuperFly Dragbar + Extra Wide 69 Handlebar
Cruiser Retro Deluxe Seat

Braking:

Shimano BR-M395 front and rear discs
Custom adaptations for mounting on unprepared frame

Wheels & Transmission:

DH 64 26" matte black rim
Shimano Alfine 8-speed hub
Street Hog 26x2.35 tires with white sidewalls

Result

Deliverable:

Unique functional prototype
Legal electric bike in Switzerland (compliant with OETV)
Aesthetic object:apparent transmission and gearing, bold neo-vintage style
Controlled budget: CHF 2,980.- all inclusive

Technical data:

Motor power: 450W / 48V
Battery: 48V 15Ah
Pedal assistance: <25 km/h
Manufacturer speed: 20 km/h (actual speed 82.5 km/h)
Homemade parts prototyping time:~60h
Research and component analysis time:~80h

This project demonstrates:

Ability todesign a complete object(mechanics + electronics + design + legality)
Custom manufacturingwhen standard components are not enough
Artistic vision: transforming a functional vehicle into a visible mechanical piece
Mastery of regulatory constraints (Swiss approval)
Management of multi-country supply (DE, HK, FR, CH) within a constrained budget