The Long Tale Of A Custom Bike Build

When you decide to do something like start a build how do you do it?

+ = ?

Probably, if you have unlimited cash you might just go to a custom shop and say "Hey guys this is what I want" and come back sometime later and pick up your ride. Sounds like what a lot of folks would like to do right? And maybe the money is not an issue but you are more of a hands on type so you farm out most of the fab stuff and just buy all the cool custom stuff you want and then assemble the ride. I mean you got that big shop and all those great new high dollar tools just sitting there so what the hell?
Oh that sounds so cool!!! I mean who wouldn't like to just spend some green and ride the damn thing, HuH?

Yeah cool! And if that's your deal man do the rest of us envy ya'll! You can bet that I like all the rest of you drool over those fine bikes at Rat's Hole or Sturgis. Those one off bikes they build on T.V. are just freaking amazing... of that there is no doubt.
They call that a "Reality Show" but who are they kidding? Alternative Reality is more like it.

+ AND = ?

Most of us can barely afford a good welder and a quality torch let alone a waterjet and the ability to buy tonight whatever need for a build. If you stroll down the line up of any car & bike show do you really give any thought to the thousands of hours of work that went into the fabrication of the rides? How many were built not on a $2000 air lift and with all the newest tools but in a old garage on a cracked concrete floor, custom crafted parts made not from a CNC and a computer program but out of raw steel and from some guy's head with a torch, hammer and file the only tools he could afford.

So anyway what's the point? Is one better than the other?...
I guess if you judge

a bike by how much money you spend in a build as the deciding factor it could be. But as you roll down the boardwalk in Daytona or go to the local burger joint show for most of us it's not the cost but the details..the uniqueness of the custom crafting...the quality and flow of design that brings that show winning cream to the top. Sure the money helps and no matter who, money is going to be spent but the real builders are the ones who have the vision..the desire and the passion to bring it all together.....
Yeah money is nice but the bottom line is you spend what you got... a choice few have the money.... and..... the rest of us hopfully have that great equalizer... TIME....

So where is this going?

I recently got the hankering to start a bike project. I have never built a scratch built custom. Sure I have been messing with and modding cars and bikes for 30+ years but never have I built anything that is totolly of my own design. I love building hot rods but only in bikes do you have the freedom to build from the ground up a ride that,except for the mill, can be a 100% custom without a huge bankroll.
My tastes in bikes are kind of uncommon as I have always had a love for big bore 4 stroke singles. So when I thought about what baseline to start a build from I of course looked to those types of bikes. But I wanted to really build something unique. I am not flush with cash so a big single that could be built and not cost a fortune would fit in line with my budget.
I want to build a bike that I could take to the track on the weekend but still ride occasionally on the street. So I tend to like the look of vintage street racers. You know the cafe racer types? I kinda like that action.

Ok, so what engine to use?
I did not have to think too hard on what motor to pick. The British singles are very nice but they quit building them a long time ago so they quite are pricey and parts are hard to find. Yeah everyone loves a classic AJS or Royal Enfield but would anyone really want to butcher up a classic for a custom? Probably not.
There are some current model mills available like the 690cc KTM Duke but then you would run into issues on emissions(they run cats) that would negate the budget minded build as well as being damn fugly.So that leaves the common Japanese models that were built during the 70's and 80's.
A good many cafe and dirt track bikes were fitted with Yamaha singles over the years. They proved to be strong, reliable motors that were receptive to performance mods and I have ridden more than a few of the dual sport versions and was always impressed with them. That seemed to be a good place to start. I found that the 500cc motors that were so common in the day have a huge following and as such are getting harder to find in good usable shape. Lots of performance parts and services for them abound but again finding a base to start with.. again tough to find.

So after much reasearch and thought I was able to settle on one of Yamaha's lesser known motors. The Yamaha XT600 & TT600 models that were made during the 80's was really a perfect fit for this project. Big,powerful and made in multitudes,they were very a unique bike that really adapts itself well for a custom application.
Both bikes were a very nicely engineered power horse with 4 valves and overhead cams, a dual carb fuel system and dual exhaust. Combined with a cdi electronic ignition made and a full pressurized oil system, this a very reliable motor that can be easily modded for serious power. There are lots of performance parts available and no emission systems to interfere with a custom build.
The two models were designed with different riders in mind
The XT is the street friendly version with a 12 volt battery system to power full lighting where as the TT was more competition suited with a 6 volt performance system.
Though motors were basically the same the TT was outfitted with a chrome plated cylinder sleeve, a hotter cam profile and a more performance oriented cdi box.

Final thoughts

Ok, this is going to be a long process... I am not going to kid anyone otherwise. I have my ideas and have settled on a bare bones platform. Now I have to find a sutable bike for the project. I hope everyone finds these posts interesting and all commentary is appreciated and welcomed. If you have similar projects that you would like to share please post them on the reader rides page or forward the to me so I can.
Happy hot rodding,
Soonerbillz