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

Freelance product and motorcycle design and engineering. Max Betteridge Design

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Belly pan mould