So, I got this idea stuck in my head a while back, think it was after seeing some seriously cool bikes kicking around up here in the North East. Not flashy show ponies, but real, ridden custom cycles. Looked tough, like they belonged on these roads. Decided I wanted a piece of that action, build something myself.
Getting My Hands Dirty
Found an old beat-up Yamaha XS650, perfect donor bike, wasn’t pretty but the bones were good. First thing, dragged it into my garage and just started tearing it down. Took photos like crazy so I’d maybe remember how it went back together. Engine out, frame stripped bare. Felt good, like a fresh start.
The frame needed work. Wanted that low-slung look. Got out the angle grinder – sparks flying everywhere, loved that bit – and chopped off the back end. Bought a simple frame loop online. Now, welding… that was a learning curve. My first attempts looked like pigeon droppings. Watched a ton of videos, practiced on scrap metal. Finally got decent enough beads to stick the loop on solid. Ground it smooth. Lots of grinding.
Parts Hunting and Problems
Then came the fun part: finding bits. Scoured eBay, forums, swap meets. Wanted specific handlebars, kind of tracker style. Found some, but had to modify the controls to fit. Nothing ever just bolts on, does it?
- Stripped the tank down to bare metal. Took ages getting all the old paint off.
- Decided on a dark green color, kinda like the forests around here. Sprayed it myself in a makeshift booth. Orange peel? Yeah, a bit. Wet sanded and polished like mad.
- Wiring. Oh god, the wiring. The original harness was a nightmare. Ripped it all out. Bought a simpler, universal harness. Spent weeks staring at diagrams, testing connections with a multimeter. Blew a few fuses, cursed a lot.
- Got a simple solo seat, had to fabricate brackets to mount it to the newly modified frame. More cutting, drilling, and bolting.
Putting It All Together
Slowly, piece by piece, it started looking like a motorcycle again. Bolted the engine back in. That was heavy work, needed a neighbor’s help. Fitted the wheels, new chain, sprockets. Connected the simplified wiring loom – fingers crossed. Mounted the tank and seat. Stood back and thought, hey, this might actually work.
The first start-up… that’s always the moment, right? Turned the key, hit the starter… it coughed, sputtered, then roared to life! Loud, obnoxious, absolutely brilliant. Had to adjust the carbs a bit, fiddle with the timing, but it ran.
The Ride Out
Took it for its first proper spin down some back roads. Felt raw, connected to the machine. It wasn’t perfect – vibrated a bit, suspension’s still stiff – but it was mine. Built it right here, inspired by that North East custom vibe. Learned a ton, mostly that things take way longer and cost more than you think. But yeah, totally worth it. Every skinned knuckle, every late night in the garage. That’s the real deal.
