Home stretch

We tear the bike down and get the frame powder coated. A view of the front swingarm and its Mountain bike shock.


The finished product less bodywork.

Test ride and details

A quick test ride of the chassis on a small grade to ensure the steering works.


Wow, it actually works.


With the chassis sorted and the bodywork well on its way we take the time out to mount radiators and manage the plumbing.


Also on the to-do list, have chris re-route the stock RS expansion chamber to fit our chassis. Very nice.

Buck finishing and lay-up

Our quick and dirty technique is as follows. The wire form gets attached to a rigid board, the black piece on the bottom, in an area that will remain open on the finished part. The foam attached to the front of the rear cowling form is in place to make the back of what will eventually be the seat.


Stretch packing wrap or seran wrap is gently wrapped around the form. I say gently because if you pull on the stretch wrap it will deform the wire form. Two layers of fibreglass are layed over this plastic to create a part rigid enough to have bondo applied to its surface and faired out to create a finished buck.


The finished bucks with a coating of mold release.


Greg and Django handle the Carbon fabric being layed-up with resin onto the finished buck.