Building the GSX400 Cafe Racer
 The day I bought the GSX |
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 First concept sketch |  Edited photo using Photoshop (before the build started) |  3D scan of the GSX with a partial CAD model of the tail pod |  Custom triple clamp integrating the new instruments. |  New front end including new triple clamp, instruments, handlebars, mirrors, and custom leather grips |  Aluminium seat pan made from templates created in CAD |  Tail-pod plug made using a stack of laser-cut MDF created in CAD |  Prototyping tail-pod using vacuum formed plastic to check fit of new lithium battery |  First layup of fibreglass in vacuum formed mould |  Tail pod fitted to seat pan |  Custom aluminium flow straighteners for new pod filters |  Ready to cut the frame. Until this point the bike has remained ridable |  Fitting the seat pan, electrics, and number plate. Also visible, the fibreglass caps on the rear of the fuel tank. |  |  Fibreglass lay-up for seat base |  |  Stitching the seat |  Completed seat with laser-engraved feature |  Custom leather wrapped grips with laser-engraved pattern and custom CNC aluminium clamps |  First ride with new modifications |  |  Improvised spray booth |  |  Custom vinyl decal |  |  |
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