By Anthony van Someren - 04 Feb 13
Arnie knew he wanted a bullet nacelle headlight, and found a 6” bucket on Fleabay from a Guzzi Stornello. The front fender came from a Honda 650 which he shortened. Making the mounts was difficult because the bike has upside down forks, so it had to mount to the lowers. Arnie finally arrived at the least obtrusive solution by replacing two of the Brembo brake bolts with longer ones and making these into the mounts.
The rear subframe was made out of band iron and steel tubing, relocating all the electronics, ECU, relays and fuse block. This took quite a bit of trial and error, tack welding and grinding. Arnie really wanted the subframe, tank, fender, and exhaust to all be parallel to the ground, with no up-swept angles, but couldn’t pull it off on the subframe without compromising rear suspension travel, seat height or and exhaust clearance."The pipes are from DanMoto, in China, via eBay. Very cheap, but appear serviceable. I try to avoid this type of product, but couldn’t pass up the price, half that of other exhausts. The metal and carbon tubing is very thin, the welds tiny. They are light. I just hope the 12 year old girl who made them did so at the beginning of her 14 hour shift, not the end." The tank is from a 1980’s Suzuki GS 1000. Arnie chopped off the front mounts, made and welded new ones to get the position right, and shimmed out the stock rubber donuts on the frame. He then welded NPT bungs on both sides, 3/8" on the left to the fuel pump and 1/4" on the right to the pressure regulator. "I cut out the side panels and welded in sheet metal for the knee cutouts. I considered the hammering method, but don’t like the way those look. This took dozens of hours, tig welding at 20 amps, barely enough to trip the sensor on the welding helmet, but plenty to burn through occasionally. Also spent nearly a day pressure testing and fixing pinholes. The tank (another eBay gem) was very rusty, even came to me with a locked cap and no key. Had it boiled out and coated at a local radiator shop." The seat is from Dime City Cycles and Arnie describes it as light as a feather and very cheap, although a little asymmetrical, and taking quite a bit of jiggering to get it on straight. Arnie's favourite part of the seat unit is that the stock Centauro tail light, turned upside down, is an almost perfect fit under the rear part of the bum stop. The turn signals are the old bar-end kind, from Emgo. The instrument is an Acewell computer, with speedo, tach, clock, and indicator lights and modes in a 2.5” diameter gauge. It includes a fuel level gauge which connects to an Acewell sender which Arnie welded on the Suzuki sender mounting plate. We think it's a superb job and right up our street at the BSMC. You can follow Arnies' own blog with more detail on the build here.