 Photoshop concept using partially exposed basalt-fibre tank, seat, and belly-pan |  CAD development |  CAD development - it was decided that the tank would not be able to go below the frame-line because that would make it too wide |  CAD development |  CAD development |  CAD development |  3D scanning the bike |  One of the 3D scans showing detail underneath the tank |  3D scan in CAD |  3D scan in CAD - the stock airbox and battery stick through the tank. The tank will need to be altered to accommodate these as well as the fuel level sensor |  3D scan in CAD - the stock airbox and battery stick through the tank. The tank will need to be altered to accommodate these as well as the fuel level sensor |  3D scan with slightly larger tank |  Modified tank to fit over battery and space for pod filters. Also tweaked belly pan and tail surfces |  Modified tank to fit over battery and space for pod filters. Also tweaked belly pan and tail surfces |  Modified tank to fit over battery and space for pod filters. Also tweaked belly pan and tail surfces |  Finally captured some 'before' photos of the bike. Now I can start pulling it apart. |  Finally captured some 'before' photos of the bike. Now I can start pulling it apart. |  Finally captured some 'before' photos of the bike. Now I can start pulling it apart. |  A fraction of the sketches required to get to this point... |  Designing and camming the new custom triple clamp |  CNC milling the new triple clamp |  New triple clamps fresh off the machine |  New triple clamps fresh off the machine |  New triple clamps |  New triple clamp fitted |  clip-on handle bars and bar-end mirrors assembled and ready to fit |  3D scanning the gauge internals. Because this bike has an immobiliser build into the gauges they can't be replaced. They look awful though, so I will repackage them to try and make them a bit slimmer. |  CADing the new gauge housing |  Mockup of the new gauge design to check the fitment and check that the CAD lines up with the internals |  Photoshop of the new CAD |  Creating the clamps for the custom leather grips |  Finished clamps for the custom leather grips |  CNC milling speedo mould |  Basalt fibre |  Polished speedo mould |  Laying basalt fibre speedo |  vacuum bagging basalt fibre speedo |  First basalt fibre speedo enclosure |  Basalt fibre speedo enclosures |  basalt fibre speedo mount |  Custom CNC speedo backplate |  Custom CNC speedo bezel |  Custom CNC speedo bezel |  Assembled speedo |  Creating headlight bracket clamps |  Stainless headlight bracket which didn't look quite right |  Creating the custom headlight brackets |  Finished headlight brackets |  Finished headlight brackets |  Prepped parts ready for anodising |  Prepped parts ready for anodising |  Anodised parts |  Laser engraving anodised backplate |  Speedo partially assembled |  Speedo with lens assembled |  Replacing green LEDs on the speedo with new white ones |  Old | New |  Custom laser-cut leather grips and CNC clamps fitted |  leather grips, triple clamp, and speedo fitted |  Custom speedo fitted with white backlight |  Adapters for the new air filters |  New Uni air filters fitted |  Bracket for mounting electrics with new air filters. Relocated: coil, ECU, relays, air pressure sensor, and LED indicator load resistors (not pictured) |  Bracket for mounting electrics with new air filters. |  Bracket for mounting electrics with oil breather removed. Relocated: regulator/rectifier and coil. |  Bracket for mounting electrics with oil breather removed. |  New | old front indicators |  Front indicators fitted |  Revised belly pan design with roll-over edge |  The initial plan to make the belly pan mould - 15 layers of 9mm MDF per side, covered in polyester bog and CNC machined back to a smooth A-surface |  Couldn't find a crankcase breather the right size so I bought a smaller one and machined the opening to make it fit |  Belly pan and tail moulds laid out for laser cutting |  Laser cut belly pan and tail moulds |  Gluing belly pan mould |  Bog skin on belly pan mould |  First roughing pass on belly pan mould |  Finishing pass on belly pan mould |  Belly pan moulds after machining |  Filling bubbles in belly pan moulds |  Bog skin on tail mould |  machining tail mould |  machining tail mould |  Tail mould prepped for gelcoat |  Gel coat applied to tail mould |  Sanding gel coat |  Polished gel coat |  Waxed and buffed gel coat |  Flattened surfaces for tail material template |  Laser cut glass fibre for tail reenforcement |  Laser cut glass fibre for tail reenforcement |  Laser cut foam core mat for tail reenforcement |  Fuel tank plug |  Fuel tank plug |  Materials prepared for layup |  Layup and vacuum bag |  First tail part |  First tail part |  Second tail part |  Second tail part |
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