Building the 'Flat White'

'Before' photo of actual bike	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

Structure inside tail part	Second tail part in sunlight	Laser cut tank plug	Laser cut tank plug	Laser cut tank plug	Shaping the laser cut tank plug	Expanding foam to fill the tank plug	Fibreglass shell for the tank plug
Fibreglass shell for the tank plug	Bogging the tank plug	Rough shaping the tank plug	Shaping the tank plug	Fibreglass seat cushion base	Fibreglass seat cushion base	Fibreglass seat cushion base	Stud for mounting seat cushion
Stud for mounting seat cushion	Stud for mounting seat cushion	Seat cushion	Building lip around the perimeter of seat cushion base	Lip around the perimeter of seat cushion base	Lip around the perimeter of seat cushion base	Shaped seat cushion	Waterjet cut fuel filler cap flanges
Belly pan layup	Belly pan mould	Belly pan layup	First belly pan part	First belly pan part	Belly pan and seat mockup	Belly pan mockup	Tail and tank plug mockup
Tail and tank plug mockup	Laser cut leather pattern for seat	Practice upholstery	Practice upholstery	Quilted top panels	Custom waterjet cut washers for attaching upholstery	Attaching the upholstery	Finished seat cushion
Finished seat cushion	guide coat on tank plug	sanded off the guide coat	Filler-primer on tank plug	Building flange using EVA foam	Building flange using EVA foam	Clear coat on tank plug	Clear coat on tank plug
Polishing clear coat on tank plug	Polished tank plugw	Filling fish-eyes in tank plug	Gelcoat for tank mould	First layer of glass on tank mould	First layer of glass on tank mould	Reenforced tank mould	Tank mould halves
Tank mould	Tank mould	Demoulding tank	tank mould and part	Tank part	Tank part	Tank and tail rough mockup	Tank and tail rough mockup
Tank trimmed and mocked-up on the bike	Tank trimmed and mocked-up on the bike	Tank trimmed and mocked-up on the bike	Tank trimmed and mocked-up on the bike	Tank trimmed and mocked-up on the bike	Photoshop render showing what I want the bike to look like