The BROS is BOSS

So I thought I better get this blog moving...

I'm just putting the finishing touches to my Honda Bros 650 cafe racer which passed its MOT this week!! I'm looking forward to showing off my first piece at a few shows, hopefully raise its profile a bit before I sell.

Heres the almost finished beauty..

plus the sound track...

 -Both wheels were powder coated with a high gloss black by a firm in Crayford near Dartford they done a great job for very little cash!
-The exhaust had standard down pipes and a Kerker end can originally, this can was swapped with a TYGA Maggot Moto that lets the bike rev really well and sounds incredible on the down revs. The kerker unit was used to get it through an MOT.

-Front end is off of a Suzuki Bandit 400 import that has Tokico calipers and twin discs but is the exact same dimensions as the originals. This has had new Hagon springs and 10 weight oil to beef them up a bit.

-The bike has a nonstandard top yoke that has risers to take the ace bars. They have also been rubbed down and polished!
-The tank was washed through thoroughly as it had endless amounts of gunk inside this was done with fuel, I had to remove the tap to speed it up a little, the tank was sent away to has the rust sorted inside and repainted by extreme custom in Essex. Who did an amazing job as ever using aluminium flake and extra lacquer to give it a unique sparkle.



-The seat foam had also been cut and needed alot of material added to fit the rear hub this was done by Lee Hutchings Motorcycle seat specialists in a day for £100 pounds and was with out a doubt the fastest part of the project I was very impressed at his speed and attention to detail.

 -Footrests where drilled many times to save weight and look cool this was repeated with the chain guard mount. These then went on to be polished up to a mirror finish along with the flywheel and clutch casings. The casings proved a huge challenge because they were painted and lacquered I removed this will glass paper and worked my way up to wet and dry and the polishing, time consuming but rewarding!

 -The idea for the seat unit was to utilise the original sub frame just lighten it and cut off all the trimmings, I done all the cutting and welding at Steven Fellows Engineering in Swanley. I kept the original mudguard and battery box I remounted the ECU on top of the battery. I used the seat frame but cut off the rear end and welded on a frame that fixed the seat down using the original steel hooks. I made brackets for the rear light that fitted inside of a aluminium rear hub, the hub was made from four pieces of aluminium sheet metal that were TIG welded by Steven Fellows. I made brackets to hold the hub on using three bolts and aluminium spacers on a lathe to clamp the whole seat unit down to the subframe with two M6 bolts.

Heres a few extra things its had done!

-Carbs were degreased stripped blown through thoroughly and rebuilt with new seal throughout.

-All four plugs were replaced with iridium items the front left plug proved very challenging as it is buried very deep in the head, Pat Higgins from Viking Classics lent me one on his home made tools made for that exact plug! Worth the trouble though as the plug that came that out looked like it had been at the bottom of the sea.

-A new battery was fitted. (yuasa)

-The final jobs included painting the sub frame, polishing the rear hub and going over the other surfaces, mounting and wiring indicators fitting headlight brackets, fixing a few earths on the bike, adjusting the steering stops to ensure the bars dont fail the tank, aftermarket footpegs, Renthal grips, levers and wing mirros.

PRMM has been stamped into the bike frame and custom parts plus the year it was made to help me keep track of what I make!

I'll be going to the race cafe very soon to show it off!

-There were a couple last tweaks that had to be made:

-The forks were taken out given 10 weight oil and bigger hagon springs to beef up the front end.

-The front mudguard is being replaced for an aluminium one the I have rolled on a english wheel to fit a 17" wheel. I will be using the original fork brace as a mount so now spacers need to be made to make it fit correctly. Im going down to the machine shop in a couple of days to finish the bike!!!