SV650 Build Story

After countless evenings, weekends and cases of beer, the SV650 Custom project was finally completed last week. I've wheeled the bike ...

With all the parts back from the powder-coaters, it's time to start putting it all back together again. I'm reassembling using the engine...

It's still not a definite "no" on getting the SV registered in Germany, however with the fibreglass fuel tank it's incredibly unlikely. S...

One thing I wanted for sure on the final bike was a black frame, as opposed to the silver one on the development bike. This of course was...

The last big job (or so I thought!) is to get the headlight fairing made. This would involve the usual process of clay modelling, and the...

So in trying to make the bike road legal, I've made several modifications since the Slovakia Ring test. Firstly, the rear number plate...

After the mammoth journey to the Slovakia Ring, which was made even longer by my buddy's underpowered Dacia towing a big box trailer with...

After finishing the fuel tank and putting the bike together it was apparent that there was a significant issue with the running of the bi...

One of the biggest issues I've had with the design to date is the airbox cover which was to incorporate a friend's development TFT displa...

Without a doubt one of the biggest challenges of the project has been the fuel tank. From deciding the material to the fuel pump, fuel le...

With the clay complete, it's time for taking moulds, and crack on with making some actual components. To seal the clay, I sprayed the ...

Having gotten the design to a place I was mostly happy, it was time for finishing the clay and to copy the design over to the right h...

The nice thing about clay is it lets you try out all sorts of new ideas quite quickly. Often whilst roughing in one idea, I'll see a scra...

In the last post, I'd just started to load up clay, which using the tiny oven I have (you can see it in the top left of the image below) ...

Before starting to put clay on the bike, the "buck" has to be prepared, so the clay will have a secure, flex-free base to sit on. If you ...