Building the GSX400 Cafe Racer

The day I bought the GSX

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

Freelance product and motorcycle design and engineering. Max Betteridge Design

All content copyright © 2020 Max Betteridge Design Ltd.

Stitching the seat