Poth, TX. 830/484-2030  mail to:

Page #2, other builds
My first bike project came at a time when my fabrication equipment was at a minimum. A cheap small lathe was adequate enough to make bushings and adapters, which was a big leap in having to make small parts with a drill press and a grinder. Having metal working machines like a plasma cutter, a TIG welder and a milling machine has always been my ultimate goal, which I have finally reached.

I acquired a tired old '83 XL600 from a good friend, through the trade-off of tractor parts. It was weather beaten, looked really sad, but in typical Honda fashion, it still ran extremely well.

At that time there was supermotard racing in Europe. It came to America, the series had the usual US influence, and became supermoto. Anyway, I wanted a supermotard styled motorcycle, so that's what I started building.

The bike was torn down, the frame was sandblasted and painted, the engine rebuilt...nut by bolt, everything was cleaned and painted. Knowing what I knew back then, it wasn't anything out of the ordinary. Searching E-Bay, I located a set of CR250 forks that was later swapped in. Since I had the equipment to powdercoat small parts, the rims, hubs and various other parts were coated in black. The 250 forks wouldn't accept the stock headlight. I  had a pair of KC off-road lights in storage, so I used what I had and created more of a desert themed bike.

I completed the bike and rode it for a while, but hated the fact that it still had the 21" front tire. I searched the internet, located a 17" rim kit and laced in the new rim. It made an amazing difference in handling and a huge improvement in looks. Eventually I'll update it to a traditional sumo headlight/#plate unit, but it'll do for now. 100 watt lighting can't be ignored....people do see me coming.
The bike is good for what it is. It's heavy by modern thumper standards, but it does make for a great highway cruiser/around town blaster. It has 100MPH+ gearing, so 70/80MPH interstate speeds is no problem.

Build album here:


Another build-up that I'm excited about is a 1975 Kawasaki H1, 2-stroke triple. Initial plans were to clean up the old machine and run it as it was, all it needed was some serious cleaning and tuning-up. It started out to be just a stock cruiser. The first complaint is that it was too quiet. It made more noise from the carburetors than it did coming out of the exhaust. So, a new set of expansion chambers was needed.
I searched for a replacement set, which is difficult to locate and expensive to purchase. Good quality replacements bring a premium price, and used ones are usually bashed in, beat up and still expensive. I ended up building my own pipes and silencers.
By now my original plans were something of the past. It needed new tires, the chrome rims had some minor rust issues and the spokes were tarnished. Chrome spokes produce a cool "twinkle" when the wheels roll, this one was lacking in that department...which I couldn't stand. New Sun rim and spoke kits would have saved weight and looked great, but it wasn't worth it to me at $650+. A more practical upgrade is to swap in a set of old (but newer) mag wheels from a later KZ550. Another step up from that is the addition of an aluminum swing arm. The one from a Kawasaki KLR250 dirt bike will stretch the wheelbase another 2 inches and won't have the flex like the stock one. The only task to making everything work is producing all the needed spacers and adapter bushings.
Even though it's not a supermoto or a dual sport, it surely deserves a place to be looked upon. These old Kawas are the '69 Camaros of motorcycles....a true hot rod. I'm not one to be limited to just one make, model or style, I enjoy having a variety.

Resurrection and build here:

You Tube vid:

The pipes turned out great, gave it a better personality....but it was still lacking in my taste for looks. I located a cheap set of KZ550 mags, cleaned them up with "blasted aluminum" powdercoating and did the swap. Since I was on a roll, I couldn't stop there. I pulled an aluminum swing arm from a parts bike. The unnecessary Uni-Track hardware was milled off, made adapter bushings and welded on a pair of shock perches....also with no mods to the stock frame.

One day on a cruise through the back country, I couldn't resist such a Kodak moment. I titled this pic "Old-n-new".

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