Rare Headlights and Other Retirement Plans

The real cycle you’re working in is a cycle called yourself.

A field guide to bike building personality types, shed psychology, and the subtle gravity of unfinished motorcycles.

The Beginning

In the early 2000s, for myself and many like me, something quite important happened.

Born in the 60s and 70s, we grew up with Wes Cooley’s AMA-winning GS1000, Barry Sheene’s Heron Suzuki RG500, and the Californian Highway Patrol, but we don’t talk about that. You could find a Ford Escort Mk1 RS parked in the street, and kids were still asking Jim to fix it for them.

Without realising it, our still developing brains were being bombarded and etched with images of endurance racer silhouettes and iconic muscle bikes.

As the millennium approached, the motorcycle industry moved on, and those icons became yesterday’s news. At this point, we realised that the motorcycles of our youth were no longer mythical.

They were very much attainable.

The once-poster icons, the Suzuki Katana, the GS1000, the angular Suzuki GSX1100EFE and the GSX-R1100 and GSX-R750, appeared in classifieds described with mechanical optimism:

“Just needs carbs cleaning.”
“Just needs some TLC.”
“Simple winter build.”

And so, our sheds filled up. Not because transport was scarce, but because our youth had unfinished business.

A legion of Generation X motorcyclists who had once used their mum’s best spoons to change push bike tyres began to convince themselves they had the technical ability to finish the work the Japanese motorcycle industry had started. We were going to take Japanese 80s and 90s motorcycle icons and re-engineer them in our sheds.

The Japanese motorcycle industry had long since moved on to fuel injection and fit-and-forget engineering principles. For our special group of plucky enthusiasts, there was unfinished business. Modern bikes became mere donors, to be sacrificed for the genetic engineering of these long-forgotten dinosaurs.

The Birth of a Tribe

Part mechanic, part genetic engineer, left to our own devices, we intrepid but crazed men of vision might have crashed and burned spectacularly at the first seized exhaust stud were it not for the birth of motorcycle forums.

These digital beacons of light and hope offered support, encouragement, technical knowledge, mass hallucination, and the collective fortitude to overcome even the most seemingly impossible technical hurdle.

And so, the tribe was formed.

Made in Japan.
Perfected in a damp shed somewhere in a suburban back garden.

We shared. We watched. We learned. Over time this new tribe established its norms.

What emerged first was the project arc itself.

Most of us had not figured any of this out yet, but we watched as others made it look easy and, through subconscious osmosis of ideas, we learned from one another.

The Seven Sacred Stages (In Theory)

In its purest form, the resto-mod arc runs like this.

Stage 1 – Buy the Donor
Hope usually exceeds actual condition.

Stage 2 – Strip and Form a Plan
Potential is intoxicating. Still in use, cereal boxes in the cupboard all have large sections of cardboard missing as the need for templates begins.

Stage 3 – Acquire or Fabricate Parts
Parcels multiply. You live on eBay. A welder, a lathe or a Bridgeport is considered a superpower. Yet more cereal boxes are needed.

Stage 4 – Dry Fit and Configure
The potential becomes visible. Snakes and ladders between Stage 3 and Stage 4 begin.

Stage 5 – Paint, Powder Coat and Polish
Money becomes irreversible. Falling back to Stage 4 is costly and embarrassing but it still happens.

Stage 6 – Assembly
For the forum, this is the most photogenic and satisfying stage of the project to watch. Your stainless steel fastener collection takes a pounding. Arguments on which assembly grease and whether stainless steel has the correct properties for brake calliper fixture erupt.

Stage 7 – Shake Down and Snag
First ride: transcendence.
Second ride: oil weep. Fuck!
Third ride: carburettor realism. Start yet another what size main jet thread.

While this list represents the full arc, the truth is not everyone completes it.

Some exit at Stage 3.
Some live permanently in Stage 4.
Some never really leave Stage 1.
Some complete it, but for very different reasons.

Which brings us to the types of resto-mod builder.

I have been watching people build bikes on build threads for over 20 years, and I have been building bikes myself for a good chunk of my adult life. I have observed lots of different approaches to the seven steps. What follows is a tongue-in-cheek take on the patterns I have observed in myself and in others.

The truth is we have all been most if not all of these at some point.

1. The Executor

The Executor respects structure.
He defines scope early and defends it. No mid-build identity crisis. No late turbo diversions.
He completes all seven stages, resolves the snags and rides it properly.
And then, to everyone’s dismay, he sells it.
Completion was the objective. Ownership is incidental.

Characterised by:
• A build brief that survives intact.
• Controlled parts acquisition.
• A properly sorted final machine.
• A classified advert titled “Project complete.”

He collects finished arcs.

2. The Keeper – The One-Bike Man

The Keeper may build like an Executor.
But at Stage 7 something different happens.
The first sorted ride does not trigger detachment.
It triggers belonging.
He keeps it.
Not because it appreciates. Not because it wins shows.
Because it feels complete.
Years pass. Quiet refinements occur. No restless accumulation.

Characterised by:
• One finished machine evolving subtly over years.
• Maintenance as ritual.
• Deep familiarity.
• No classifieds browsing.

He exits the cycle by staying put.


3. The Minimalist – The Sufficiency Engineer

The Minimalist travels only as far as necessary.
He buys carefully, not rare, not catastrophic, just structurally sound.
He upgrades what materially improves the ride.
He ignores cosmetic escalation.
He finishes efficiently.
He reaches a functional Stage 7 and stops.
No marginal-gain obsession. No dramatic reinvention.

Characterised by:
• Sensible suspension improvements.
• Clean electrics.
• Rapid path to rideable condition.
• A motorcycle that gets used.

Enough is enough.


4. The King of Cool

Sitting between the Executor and the Minimalist is a more instinctive creature.
The King of Cool understands proportion.
He knows exactly which forks, which wheels and which stance will harmonise. He balances factory lineage with contemporary sharpness. The engineering is solid, but the silhouette is everything.
The loom might not be invisible.
The underside might not be concours.
But the profile? Perfect.
It photographs effortlessly. It becomes cultural currency.

Characterised by:
• Strategic use of premium, visible components.
• A bike that “just sits right.”
• Strong aesthetic coherence.
• Social media traction exceeding mileage.

He builds icons, not just motorcycles.


5. The Nearly Builder

The Nearly Builder thrives in Stages 1 to 3.
Stage 2 feels like genius.
Stage 3 feels like momentum.
Then divergence creeps in.
A better idea appears. Another direction suggests itself. The identity of the machine becomes fluid.
Stage 4 becomes hesitation. Stage 5 becomes overthinking. Stage 6 may or may not arrive.
He often exits before Stage 7.

Characterised by:
• Competing upgrade paths.
• Parts accumulation without integration.
• “Thinking of changing direction…”
• Workshops full of intention.

He does not fail.
He disperses.


6. The Never-Ending Build

This is not indecision.
It is deliberate suspension.
The Never-Ending Builder lives in Stage 4, the dry build.
The machine is perpetually close. Close enough to imagine completion, not close enough to conclude.
He revisits geometry. Adjusts stance. Reconsiders finishes.
Completion would introduce finality.
Finality would introduce the question, what next?
So the build spans years, possibly a decade.
It may get finished.
It may not.
For him that does not matter.

Characterised by:
• A project permanently 85 percent complete.
• Repeated mock-ups.
• “Still dialing it in.”
• No urgency to reach Stage 7.

The build itself is home.


7. The Hoarder – So Many Projects, So Little Time

The Hoarder masters Stage 1.
Acquisition is reward. Rare parts are security. Possibility is currency.
Stage 2 occasionally happens. Stage 3 sometimes. Beyond that urgency evaporates.
Frames rest in formation. Engines wait patiently. Shelving improves annually.
Completion is optional.

Characterised by:
• Multiple dormant donors.
• Rare components awaiting hypothetical builds.
• Storage expansion as a secondary hobby.
• Minimal forward momentum.

He collects beginnings, not endings.


8. The Innovator – The Rosette Hunter

This builder operates on a different plane.
He does not just want to finish.
He wants to advance.
Every build is a technical statement. Factory design is a starting point, not a boundary. He redesigns everything, hides wiring not for neatness but for purity and machines bespoke components rather than compromise.
Innovation is the metric.
But beneath it lies something precise.
Validation.
He wants recognition from his peers as a true innovator.
Best Modified.
Front cover.
Judging panel acknowledgement.
Stage 7 is not the test ride.
It is the awards ceremony.
Unlike the King of Cool, he works quietly. Progress photos stop. Details are withheld. Originality is currency and currency invites imitation.
Industrial secrecy is discipline.

Characterised by:
• Obsessive finish standards.
• Money no object.
• Concealed builds prior to show debut.
• Tolerances exceeding factory specification.
• A launch timed to a show calendar.

He completes arcs, but for recognition.


9. The Racer

The Racer exists in a different universe.

He is restricted by the regulations of his class.
Form follows function.
There is no luxury for frills.

Weight reduction is everything.

If a part does not contribute to speed, reliability or legality, it goes.

The suspension often costs more than the bike.
Tyres are consumables.
Bodywork is sacrificial.

He does not polish.
He measures.

He does not chase Instagram angles.
He chases lap time.

Characterised by:
• Compliance with class regulations above all else.
• Suspension investment that borders on obsession.
• Weight reduction as a philosophy.
• A bike that looks unfinished but is brutally purposeful.
• Lap times as the only metric that matters.

He burns possibility instead of storing it.

You’re every woman, it’s all in you.

The truth is we can each of us be all of these builders at different points in time.

There are times when we execute with discipline.
Times when we accumulate.
Times when we refine endlessly.
Times when we need applause.
Times when one bike is enough.

Sometimes our sheds simply reflect the stage of life we are in and the space our heads occupy.

So maybe the types are not identities, they are closer to weather systems.

Sometimes you need the focus of a clean build.
Sometimes you need the comfort of potential waiting patiently in the corner.
Sometimes you need the audacity of innovation.
Sometimes you need to prove something, even if it is only to yourself.

If you are happy in the process, that is what counts.

If the hours absorbed in geometry, wiring and seized fasteners give you calm, purpose or even just distraction, then the project has already done its job.

The weight we carry.

A final word of caution: you can’t take it with you. It’s not 1999, it’s 2026.

In 30 years, every donor, every rare headlight, every perfectly balanced stance will either belong to someone else or will be scrap. Possibly both, in sequence.

Stuff has its own emotional inertia. It gathers meaning simply by remaining in place. It convinces you that because it exists, it must eventually become something. Three projects feel heavier than one, not physically but psychologically. Potential becomes obligation.

That weight is subtle but significant.

Be aware of it.

Keep what energises you. Release what quietly anchors you.

Because the motorcycles were never really the point.

As Robert M Pirsig so succinctly put it, The real cycle you’re working in is a cycle called yourself.”

And that is the only one that actually matters.

Speed, Luck, and Time

From the Throttle to the Hobble

Youth

In the 1980s, in my teens, I wanted nothing more than a Suzuki Katana, all angles and attitude. By twenty I had my first taste of the barely civilised excess of a Suzuki GSX-R750.

Back then I was convinced horsepower was a kind of secular grace, bestowed not on the meek but on the mechanically devout. If you understood it, if you respected it, it was meant for you. The rest of the world simply had not been initiated.

I did not just love horsepower. I thought it belonged to me, as if it had been waiting patiently for my worthiness.

And tied to that was the larger delusion, immortality.

It was not that we thought death was impossible. It just seemed unlikely and, more importantly, misdirected. It happened to the unlucky, or the careless, or someone who miscalculated in a way we never would. We believed in our reflexes the way believers trust scripture.

The immortality of youth was not bravery. It was ignorance layered over resilience. We healed quickly enough to mistake recovery for invulnerability. If we survived a particular corner or decision, we took it as confirmation of judgement rather than luck.

Many did not get that confirmation.

Some names exist only in old photographs. Some bikes were never rebuilt. The margin between those of us who grew older and those who did not was often measured in inches and timing, not virtue.

At fifty-eight, cold and damp weather runs an audit on my body. Old injuries, half remembered crashes, years of throwing myself at the countryside, surface in my knees, lower back and shoulders like quiet accountants. I hobble first thing in the morning when the temperature drops. There is an accumulated record now, a ledger of consequences that teenage me would have dismissed as hypothetical.

Back then pain was temporary and abstract. Now it is historical.

That is the shift age brings. Horsepower no longer feels like a divine gift bestowed on the righteous. It feels conditional. Borrowed. The machines still offer power, but my body negotiates the terms.

At seventeen I thought speed proved I was meant for it.
At fifty-eight I understand I was simply spared, often by luck, sometimes by instinct, rarely by wisdom.

The impetuousness of youth made us feel eternal. The damp in my joints tells a different story. Somewhere between the throttle and the hobble is a more honest account of what it means to have survived.

Grown Up Things

By the mid-1990s I had my first mortgage. By the end of the decade I was a father and a husband.

The bike went into storage. It became impractical, a word that enters a man’s vocabulary sometime between his second child and his first term life insurance policy. I had acquired responsibilities more important than me. I developed opinions about mortgage rates. The most dangerous thing in my life was a petrol driven lawnmower.

When I became a father, and more to the point when I became the man the bank and the family both depended on, I understood the expectation. There is that line, “When I became a man, I put away childish things,” from the First Epistle to the Corinthians. It suggests a clean break, a moral upgrade, as though maturity is simply deletion.

From the outside that is probably what it looked like. The bikes went. The risk narrowed. Sensible car. Sensible hours. If you had inspected my life, you would have found no visible trace of the old compulsion.

But the truth was closer to addiction than reform.

An addict can appear clean. He can function, pay bills, raise children, show up early. No tremor in the hands. No residue in the bloodstream. The behaviour stops, but the appetite does not evaporate. It waits.

That was what it was like with motorcycles, with speed, with that teenage conviction that horsepower meant something metaphysical. I did not stop wanting it. I quarantined it.

Internally there was never any doubt. Not once did I believe I was over it. I was simply not using at that time. You do not become an ex-addict. You become an addict who has reasons not to use.

Fatherhood gave me those reasons. Provision gave me those reasons. Responsibility built a perimeter fence around the old appetite. I stayed inside it as long as I could.

But beneath the discipline was absolute certainty. Not hope. Not fantasy. Certainty.

One day I was going to use again. That knowledge did not make me reckless. It made me patient.

From the outside I had put away childish things. Inside I had preserved them at low heat, like coals banked overnight.

It was not long before the internet and broadband arrived and I discovered motorcycle forums.

They were brilliantly narrow. Entire arguments about oil viscosity. Four-page debates about carb jet sizes. Men from across the world posting grainy photographs of motorcycle parts as if they were medical scans. There was little performance of personality, just solid information and occasional dry sarcasm. In retrospect it was group therapy combined with serious technical knowledge.

It was my gateway drug, a way back in. A forum full of fellow addicts, most of whom were openly using again and dressing it up as a legitimate hobby.

At night, once the house was quiet, I would go out to the workshop I had built in the garage. Not far, just twenty paces from the kitchen. I was not vanishing, I was checking something. Out there sat whatever unloved 1980s relic I had dragged home. I told myself I was restoring history. In truth I was restoring a version of myself.

Rebuilding an old engine is honest work. You cannot sidestep a seized head stud. You cannot fudge valve timing. Either it works or it does not. Compared with the rest of my grown up life it felt almost spiritual.

Other like minded souls were performing the same ritual in their own sheds. We never said we needed it. We just asked and answered technical questions. It was camaraderie without confession.

When social media began to replace forums, I spent the second half of my forties, along with my Dutch friends, rescuing oldskoolsuzuki.info from slipping into oblivion. We did that because we felt an obligation to those who still wanted it and needed it. I am glad we did, and I am glad it is still doing what we worked so hard to ensure it would continue to do.

Wisdom

Now I am fast approaching sixty. The children have gone. The mortgage has gone. The time I once fought to steal is suddenly available in broad daylight.

The forums are all but gone, replaced by social media streams that seem less interested in carburettors than in outrage. I can find a hundred opinions on politics in seconds. Finding a coherent, technically useful thread is far harder. Algorithms feed content designed to trigger a response. Friends’ groups live in echo chambers. Division has replaced unity.

I have more bikes than ever now. They share one thing in common. I can maintain them all myself. Some I built from scratch, some I have rebuilt extensively, but mostly I maintain them and I ride them.

Now it is different.

I am riding more miles in a year than I probably did in my entire forties. Proper miles. Crossing half the country before breakfast. Taking the long way without apology. Loading the bike and disappearing for three days, camping under cold, indifferent stars with like minded souls who ride well, drink well and laugh heartily round an open fire. This life fulfils in a way no thread ever did.

The garage is no longer a refuge. It is a workshop in the literal sense. Maintenance and repair when required. The stable kept fit because the point now is not rebuilding but riding. The machines exist to move.

I am not pinned between a garage bench and a glowing screen any more. If I want to ride, I ride. Midweek. Early morning. No need to justify it. That freedom is both gift and warning.

Because I know it is conditional.

Bodies change. Health shifts without consultation. Friends disappear. Weather closes in. The window is open now, but I am not naïve enough to believe it will stay open indefinitely. That awareness sharpens everything. While I can swing a leg over and feel steady, that is exactly what I intend to do.

I want the real world. Damp tents. Campfire coffee. Engines ticking as they cool. Conversations that do not require Wi-Fi. Laughter that does not need punctuation. I am grateful for the online years. Those forums were a lifeline. We built something solid there, an informal, unsentimental support group disguised as mechanical advice. It mattered. I will maintain my commitment to keeping oldskoolsuzuki going, because I know how important it remains to many.

But for me, this phase of my life demands something else.

It demands that I exploit the freedom I worked decades to earn. Not recklessly, but deliberately. Use the miles while they are available. Share roads with people whose faces I can see and whose hands I can shake.

I do not feel the urge to narrate it any more. I do not feel compelled to post proof of motion. The validation I once got from a reply notification now comes from riding an open ribbon of tarmac with like minded souls, knowing I am going to laugh and drink round a fire tonight and then do it all again the next day.

At forty-five, rebuilding a bike felt like reclaiming my youth. At fifty-eight it feels more like negotiating with gravity. I make old man noises getting on and off my bikes. I have friends who no longer ride, not because they do not want to but because bodies make decisions pride cannot override.

Mortality is less abstract now. It sits in the garage with me, somewhere between the toolbox and the paddock stand.

That sharpness makes things clearer. The ride itself matters more than the build thread documenting it. The conversation and a cigarette at a roadside stop beats any online exchange. Standing with friends of a similar vintage, helmets off, laughing about how much our bike gear shrank over winter, feels more solid than any digital affirmation ever did.

In my twenties motorcycles were a calling. In my forties they were therapy disguised as maintenance. In my sixties they will be something else entirely, a deliberate choice to remain engaged with risk, skill and other human beings in real space.

I still enjoy the shed. I still enjoy the smell of fuel and warm metal. I simply no longer pretend I am rebuilding youth. I ride not to escape life, but for life not to escape me.

The irony is that we spent our middle years escaping into garages and forums to cope with adulthood. Now that we finally have time, we realise what we were really after was not escape at all. It was presence, with a machine that demands attention and with like minded people who understand why that demand still feels necessary.

Hamamatsu III – The History Stuff

Being a good student, I already had some of the history of Hamamatsu down to an ‘elevator pitch’ but let’s see what I missed. The bikes were not going anywhere but I was still teasing myself with thoughts of what the top floor had in store for me. First I had to make my way through the manufacturing exhibition.

As you’d hope, there was some interactive stuff. Pulling levers to rotate a car door on a fully automated robot production line was a good one -great sounds. I knew from a little inside tip that there was another machine which would deliver me a Suzuki egg! (It had a car in it … booooo) You were walked through the casting process and got to see some models too.

Can ya tell what it is yet?

I’ve got a bit of a thing about casting since making my own ally ashtray in Big Pete’s GoP many moons back …

There was some stuff around the factory itself and the sheer scale of the site can be seen from the aerial photos taken through the years. (come on! get to the bikes already!)

Hamamatsu from the Air
Suzuki – Mission Statement

I moved up to the next floor and came pretty much face to face with The Man Who Started It All. Not the most recognisable face, sure but here he was. The man who had used his engineering skills and business acumen to redirect Suzuki from a failing loom making business, to an upstart car manufacturer closed down by the war as ‘non essential manufacturing’ , reinvented AGAIN as a motorcyle and small utility manufacturer, and onto the business that continues to thrive today. It was pretty emotional. Plus, I hadn’t really spoken to anyone all day and this guy was willing to listen a while.

The man of ingenuity – Michio Suzuki

And finally – here they spread in front of me, I CAN SEE THE BIKES! Be cool. Breathe.

Suzuki: In the beginning …

I’m still on early history trip now and am duly reminded that from day 1 the business purpose was to serve its customers. Right now there was a gap in the market for cheap and easy to maintain transport that everyone could use. Suzuki’s engineers calculated that 36cc gave sufficient output having been combined with a pedal drive and the Power Free E2 was born in the early 50s.

The handsome Diamond Free model

Development continued at pace in Hamamatsu. It was 1954 and the team were set up at the prestigious Mount Fuji hill climb – it was show time. Their win there in the 90cc class put them firmly on the manufacturer’s map. They were contenders.

As well as speed and power trials, Suzuki also wanted to demonstrate the reliability and tenacity of their new machines. A pair of brothers spent 2 years riding this ‘Diamond Free’ 58cc model 47000km between Bangkok and Paris. The road network was barely developed at that point and you can only imagine the challenges along the way, but the machine survives to this day, on show here in Hamamatsu.

By the early 60s. Suzuki were ready to take on the world renowned challenge, the ultimate test of rider and machine – the Isle of Man TT Race. The team ran machines from 1960 but it wasn’t until Mitsuo Itoh took the ride in the 50cc class on the RM63 that Suzuki got to lift their first TT trophy.

The TT winning Suzuki RM 63
The RM63 – small but powerful!
Suzuki for the Win! Eat My Dust.

Keep posted as I head further into the 60s, 70s and dip a toe into what Suzuki had in store for the 80s

Oldskoolsuzuki meets Don Hill at Rooster Racing

Rooster Racing Don Hill

At the end of January I got a chance to go and visit a man who has probably forgotten more about building and tuning 90s GSXRs than most of us will ever know. His name is Don Hill and he owns Rooster Racing.

What made this opportunity to visit Don’s workshops special was that it’s not something he offers very often. He is almost adverse to attention and publicity, preferring to hand pick the people he builds bikes for. The reason for Don’s approach became clearer as the day wore on.

Don Hill rooster racing Donington endurance legends oldskoolsuzuki
Don Hill and the Rooster Racing team at Donington endurance legends 2018

Don Hill

I first became aware of Don’s work when my friend Adrian McCarthy (AKA Mole) told me he was going to be one of 3 riders racing Don’s Rooster Racing GSXR powered Harris at the 2018 endurance legends event at Donington. When I was there, I got a quick look round the bike in the pit garage. The build quality and the finish were something very special.

That same year I started my own race career ( if you can call it that). Racing at Eastfortune on my home built GSXR1100 Slabside. I quickly learned that 3 of the fastest GSXRs in my post classic senior class were all built by Don at Rooster Racing. I would like to say that’s why they were so much faster than me but the truth was that was entirely down to me. With Don’s Slabside based 1216 engines routinely and reliably knocking out over 160 bhp, I can’t see my home built Slabby getting close even if my riding skills improve.

Adrian McCarthy's GSXR1100 Don Hill Rooster racing
Adrian’s Championship winning GSXR1100 slabside built by Rooster Racing

I got chatting to Don in the pits at Eastfortune last year between my races. I had been suffering from some fuelling problems and Mole and I and the rest of the team had been struggling to solve the problem. Don turned up and took around 2 minutes to sort it. We chatted again after my last race and he agreed that I could come down and learn more about what he was doing and write something for OSS.

Rooster Racing

There were two main reasons I was intrigued to know more about Don’s work. Firstly, I was impressed by the performance and the reliability of the engines he was building. Secondly, Don’s talents don’t stop at engine building and tuning. He fabricates the frame and swingarm modifications, builds his own exhausts systems and as if that wasn’t enough, he produces the most amazing paint work too. There aren’t may people who can single-handedly build a race bike to such a high standard. I just needed to know more.

Mole was going down to Don’s to pick up freshly painted body work and wheels for his 2019 wet bike. So I hitched a lift down to meet Don on his his home turf and learn more about the work that he does.

When we arrived Don took us into his main hanger size workshop, he put the heating on and then presented us with us with tea and bacon butties. I liked him already.

While Mole and Don talked I had a wander round looking at some of the motorcycle exotica that peppered the workshop.

Don Hill
Don and Mole talk shop

GSXR Engine tuning

Don was in the midst of building a new Machine shop for his gas flow bench. The flow bench was situated in another location until Don has completed the extension. Don promised me a return visit when all of the work was complete so that we could do a more detailed feature on it.

,We talked about his fastidious approach to head work. He will routinely spend 200 man hours on a head between porting it and gas flowing it. When we talked about costs, I quickly worked out that he probably ends up earning about £3 an hour on a head. It was at this point that I started to realise Don was an out and out perfectionist. He was not motivated by cost or profit. His motivation was quality. This was not Don’s day job either.

Don explained his method of gas flowing a cylinder head. Don would always gas flow with the carbs on. Not any old carbs but the actual carbs that were going to be used on the bike. He acknowledged that everyone had their own approach but this was his. Engines were built to each racers specific requirements. Those requirements often came down to where the bike would be raced and how and where the rider wanted the power to develop. No one engine would be the same.

Rooster racing
Don explains the varying engine characteristics that he has tailored for different racers

GSXR frame fabricaion

Don had a GSXR slabside that he was mid way through building for a racer from the ground up. This included all of the frame and swingarm mods and a very trick aluminium breather tank.

Rooster Racing GSXR
Ground up Rooster Racing GSXR Slabside race bike

GSXR exhaust fabrication

Don then talked us through the exhaust systems that he builds to go with his engines. He talked about about the importance of narrowing the headers at the manifold and ensuring that the pulses from the matched cylinders worked in unison at the collector box. I was out of my depth but I nodded like I understood.

Rooster racing hand made GSXR exhaust
Rooster Racing’s hand made exhaust systems
Don Hill Rooster Racing exhaust
Don explains the virtues of collector box configuration

Rooster Racing paint

Mole’s freshly painted body work and wheels were laid out for collection and they were perfect. Don was clearly a man of artistic talents too as he explained his love for ornamental wood carving and shared some pictures of his work. Looking closely at the paint work than Don had completed for Mole, it bore all of the hallmarks of a perfectionist, just like everything else that Don put his hands to.

Don Hill Rooster Racing
Mole inspects his new paint job by Don Hill

Quality and integrity are inseparable

As the morning wore on and Don and I talked some more I realised what a rare individual he was. When I say this, I mean Don seemed to be able to bring the the same methodical, well rehearsed quality, to everything he did. There was also something unique about the way Don viewed the bikes and the riders that he worked with.

When he built a bike for someone he maintained an genuine ownership like concern for the bike and the rider’s fortunes. This was the reason Don chose those who he built for so carefully. He had to be sure that they the rider would be prepared to do things Don’s way. He doesn’t build parts of bikes, he builds a complete performance package. The performance came from each part of the bike working in unison.

Mole was a trained motor mechanic and was no stranger to building his own machines. He had won a number of championships on his own builds but since meeting Don he now deferred to Don on all major decisions on race bike performance. As Mole put it “when Don tells you to do something you don’t argue you just do it”

Rooster Racing Don Hill
Rooster Racing’s Harris Endurance bike

I left Don’s workshop with a deep respect for his skills and his ethos. Don understood the high stakes for a racer, having raced for many years himself when he was younger. Racers had partners and families to provide for. The performance, reliability and ultimately the safety of the machines Don built meant more than just winning. Lives were at stake and that responsibility was something that weighed heavily on Don’s conscience.

I concluded that Don was a man of great skill, who would always put quality first. He would never be afraid to walk away if he felt that his approach was unwelcome, unappreciated or compromised. His commitment to that approach and his integrity left me feeling that I could implicitly and completely trust Don. I can’t think of a more important time to trust someone than when they’re building you a race bike.

Oldskoolsuzuki will return to Rooster Racing later in the year. In the meantime, don’t call Don, he’ll call you.

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Bike of the Month – May 2018

This month’s bike of the month is a tale of both resurrection and evolution.  Plucked from an insurance sale, this slightly fire damaged, pretty standard machine was rescued by nightrider. It was quite a rare find – especially the other side of the Atlantic. The decision is what we at OSS would call ‘a no brainer’.

We’ve been watching the story of this machine since the oldskoolsuzuki.info site itself was resurrected and as is often the case with projects progress sometimes stalls. Over the last 3 years we’ve seen a pragmatic mix of make do (when the OEM spares are hard to get) and mend.

With some advice and moral support from folk who have done the same thing as you and the balls to give it a go (or know when to sub it out) most obstacles can be over come. The proof is in the riding but this ES is easy on the eye in that striking blue squareness it wears so well.

So the GS 1100 ES has now returned to it’s rightful duty as a smile inducing muncher of miles. And I have no doubt the story and evolution will continue.

 

It’s a great bike. Who wouldn’t want it in their fleet?

Read all about the build  project here

Or throw your green eyed congratulations in nightrider’s direction over here

Congratulations to our Winner!

 

 

Bike of the Month April 2018

2 strokes… the smell, the noise, the power band, the teenage memories, your first (indicated) 100mph. Some of us grew up around them and personally I still have a hankering for one. A lovely X7 would make an excellent choice.

Speaking of excellent and X7 in the same sentence, it was time to choose this month’s BOTM and when I saw alfiestorm’s finished bike it had to be it.  When did we last have a bike of the month without cams?

As many projects start, it was bought originally to simply do up a little and get it MOT’d and on the road. Upon investigation however it soon transpired that there more work to do and indeed an opportunity to make it really nice.

The bike was dismantled, the engine was stripped, rebored and rebuilt. Lots of powdercoating and paintwork.

The tank was found to be really nasty and full of filler. Lots of work done and oh… those spannies! The result is a bike that looks ‘period right’ yet isn’t pretending to be standard… much like the one I’d have loved to have had back in the day.

So alfiestorm, your lovely little X7 is this months BOTM.

Read the project thread here.

Discuss this article here.

The quality is remembered long after the price is forgotten

At the beginning of August oldskoolsuzuki took a stand at the VJMC show at Donington. I decided I would go down for the weekend and hang around drinking beer and looking at bikes.

As the weekend progressed and my bike ogling and beer drinking continued I began to reflect upon how much my personal opinion on what constitutes a desirable bike has changed over the last 25 years.

Looking back to when I was in my 20s  my opinion was driven almost entirely by 1. Aesthetics and 2. Affordability. If I liked the way a bike looked and it was affordable, I would buy it. Even in my 30s little had changed when I bought a tatty 1982 Suzuki Katana for £500. From the age of 13 when I first set eyes on the Katana’s crazy German/Japanese design,  I had wanted one.

Although my work on the Katana started out with a largely aesthetic goal in mind, I was quickly drawn into a very different mindset. My journey led me me beyond aesthetics alone, into the world of functional performance parts that, to the untrained eye, often looked awkward or even aesthetically out of place. If you knew their significance, however, they took on a functional beauty all of their own.

So, my view of what constituted a desirable bike had gradually distorted. What makes a desirable bike for me, these days, hinges almost entirely on the sum of it’s parts rather than the whole. More accurately, form now follows function.

Where once I would stand back from a bike to take in it’s lines and evaluate it’s stance and other wanky bullshit of that nature, I’m now more likely to be found crawling around underneath it, taking in every bolt, bracket and component. If it has the right parts and it has been well put together, to me,  the engineered, functional simplicity, that some might find ugly, becomes a thing of great beauty.

We now live in the world of Facebook Instagram and Twitter and there are more shared opinions about what is right and what is wrong than ever before.  My opinion is just one more of the many opinions shared and although I represent a unique type of anorak, I live happily with the knowledge that I am not alone and I have a place to go, away from the internet, to indulge my world view.

I still remember when OSS spent a few agonising years on Facebook while the forum was up on the ramp. The problem with most of the open and untethered internet is that literally anyone can pitch up and offer his or her opinion on content and knowing what they are talking about is purely optional. I remember on the old Facebook page someone had posted up a picture of a really nice EFE fitted with a turbo. It’s fair to say that a more brutal looking engine and assembly of purposeful plumbing, would have been hard to find. While most of us were liking it and fawning over it, one learned chap commented, with great authority, that he didn’t think the oversized frame tubing looked very good and that it ruined the lines of the bike. Somebody quickly corrected him on the fact that this was actually the feed from the turbo to the plenum and not the frame tube. “I still don’t like it” he replied ” it looks out of place and ruins the lines of the bike”.

Every time I see an overpriced CX500 cafe racer with a brown leather seat, bathing in the glow of an Instagram filter, I am reminded that there are many who will never see beyond style alone. Each to their own. Fashions come and fashions go but quality never goes out of style.

A walk around any race paddock and you quickly realise that these guys have always believed that function dictates form.

 

We built oldskoolsuzuki.info so that we would not be alone in our lust for expensive components, trick engineering and the love of admiring the work of  those that are able assemble said parts to form unique performance motorcycles. Looking around our stand at Donington, I was reminded that we did the right thing.

Quote of the weekend at Donington goes to a passer by on our stand, who after taking a long and careful look around the bikes on the stand, turned with a smile and said “you guys are fucking mental!” Naturally, we took that as a compliment.

So here is to continuing to beg, borrow and engineer  the very best parts we can, safe in the knowledge that the quality always remains long after the price is forgotten.

Members discuss this article here

A picture paints a thousand words……

Brian O'Shea 04 a

When we re-launched the site we were keen not to fall into the traps that  the previous forum had suffered from. As we saw it ,those were bandwidth issues and forum maintenance issues.We also wanted to fund the site independently and transparently, without donations.

Bandwidth

So as far as the bandwidth issues were concerned we decided to host the entire site remotely. In order to keep hosting costs low we restricted the size of uploads ( pictures) In the time that the site was down everyone naturally and understandably became very used to the seamless and automatic picture resizing prowess of platforms like Facebook. This meant that resizing images prior to posting had become a total pain in the arse. We now believe that this is ultimately affecting the desire for members to share pictures and content on the forum. We concede that this is counter productive.

Forum Platform

We trialled a few platforms before we settled for IPB. The platform is fully supported  by the company that makes it which means we don’t have to do do much to keep it in good health.  It is mobile responsive and offered the best balance between cost and  functionality. Unfortunately it did not have a picture resizing plug in that would allow any size of picture to be uploaded and resized automatically. We hoped IPB would develop this but they have not, yet. This lead to many members using photobucket and other picture hosting platforms to save having to resize pictures.

Picture hosting

Now, while remote hosting of pictures from your own account is easier than resizing as well as being easier on our storage capacity it’s not ideal for  the info stored in the threads. The reason for this is that photobucket links break for all sorts of reasons. For instance if you delete pictures on your hosted account then the links on the forum no longer work and threads that were once full of pictures fill up with annoying black boxes with a message saying that the image is no longer available.

We like pictures

So, here’s what we have done to remedy the situation:

  • You can now upload any size picture that you want. We have lifted the restriction on file size.
  • We want to store all site pictures here rather than hosting them elsewhere.
  • When we need to we may have to increase our hosted capacity but that wont be soon.
  • Use the yellow link which says choose files to upload your pictures.
  • We have also repaired the glitch that was affecting hosted pictures links.

We could have just said “we’ve fixed the picture problem” but we wanted to take the time to explain what we where trying to achieve as a way of explaining the decisions we have made. Communication black outs were another pit fall we wanted to avoid.

Please do your best to keep file size down and help us save space. We will routinely delete pictures from the for sale and wanted sections once the posts are dead, in the interests of maintaining space.

Happy posting.

Discuss here

Horsepower talks and bullshit walks

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There are few points in a bike build that have more potential for self back patting and/or self loathing than the inaugural visit to the dyno man.  It is the place where  a curved line graph and 3 magic digits coldly define the fruits of a long winter spent chasing those elusive extra horses.

Dyno runs don’t normally come cheap but thanks to OSS member Havoc ( Tom Davidson) we have secured the use of a dyno provided by RTR in Nottingham. Dyno sessions will be 20-25 minutes for just £25. Each dyno run will come with a full print out as well as advice from RTR’s proprietor.

The date for the planned dyno day will be Sunday the 31st of July starting at 10am and it will be held at RTR Motorcycles,  7 Moorbridge Road, Bingham, Nottingham NG13 8GG. The venue is just 2 units down from Allens Performance so we will try to arrange carb jets to be available for tweaks between runs.

In order to make the day financially viable we’ll need 12 people so once we have 12 people paid up the event will go ahead. If we don’t have 12 people by the end of May we wont do the event. Details on how to sign up and pay can be found here on the forum. If we have more than 12 people and our costs are covered  any surplus will go to the air ambulance fund.

Tom has also arranged for a catering van so that members can keep up their strength on the day.

If you are looking for a dyno run to set up your bike or you just want to know what it’s pushing out at the back wheel £25 is not a lot of money.

Naturally we will start a competition where members can claim a  BHP figure before the start and depending on the results we might resurrect the OSS bullshit award for the biggest difference in the dyno result.

Please bear in mind that your bike’s mechanical well being  is entirely your own responsibility and OSS takes no responsibility for mechanical failure  or any resulting mechanical damage that may occur  during your dyno run.

Raiders of the lost KnarF

Rene is on location today so he asked me to publish this article on his behalf.

Many of you will instantly recognise the name knarF and you will know the importance of the OSS build project associated with it. For those that are new to OSS, we need to provide  little bit of background.

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On the 13th of July 2006 the OSS community lost a close friend KnarF (Frank) when he died suddenly due to freak allergic reaction to something he ate while on holiday. At the time, we only learned this sad news quite a bit later when Mr7/11 (OSS site founder) was contacted by KnarF’s family to ask “what to do with all those bike bits”. Like so many of us, Frank had been collecting parts to build his dream bike for a number of years, while still always having a fairly tricked out bike on the road, it’s a familiar OSS condition.

After getting over the initial shock of loosing a close friend ,  Mr7/11 spoke with KnarF’s family and agreed it would be a fitting tribute to try to complete and realise KnarF’s dream of a  Yoshimura GS build.  Mr7/11 came back to the OSS community and asked that we all share that commitment to build Frank’s dream bike. Mr7/11 saw this is as his and the OSS community’s obligation to Frank and his family; to posthumously build the bike Frank had been dreaming of but would sadly now never  have the opportunity to complete.

Thus the  KnarF GS build began. The project  got it’s own  board on the forum and a legend was born. Parts were gathered from all over the world and the whole of OSS community  rose to the occasion lending their support  through parts, engineering, painting, powder coating, tuning, expertise , know how, encouragement and enthusiasm.

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Mr7/11 led the project, with a lot of help from many generous site members. We all watched as Frank’s dream bike took shape before our very eyes. The KnarF GS was finished in 2007 in time for the deadline and revealed to the world at Circuit Park Zandvoort .

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The bike was track tested at Assen and I still remember standing in awe as the bike went through the pit lane at onto the track to do what is was made to do. I watched with a sense of great pride as it promptly slaughtered a H#nda Fireblade on its maiden laps.

NP7L4985 (1) NP7L4980 NP7L4941 (1) NP7L4917 NP7L4896

After the KnarF GS  first appeared at Assen , it was campaigned for a good year or so as a proper classic racer by a site member Ron. After a while news  of Ron and the KnarF GS went quiet. Ron went missing and with him the Knarf.

I never gave up hope of finding the KnarF GS again and over the years I picked up  rumours and snippets of information about it’s whereabouts and it’s well being. More recently there were talks about  it being found and returned but as it so often  goes with some things, for one reason or another they were never followed through. I kept hoping  that it would one day magically turn up.

Those hopes finally  became a reality when I recently got a message from  Fred on my phone; “call this number”. When I did I found my self speaking to a guy  who I don’t personally know but who appeared to be familiar  with all things OSS. Most importantly he told  me he knew where the KnarF bike was.

In the end it turned out it ended up in the hands of a mutual friend, who was unaware of what the bike was and what it meant to a lot of people. Most importantly he agreed to return the bike to the OSS community.

So today marks the return  of a long lost friend and the story of this bike and the community of OSS, who built it continues.

KnarF 1KnarF 2

July the 13th 2016 will mark ten years since we lost our friend KnarF. It gives me the greatest pleasure to announce that we will  be setting out to get the bike back to the state and specification that it was in  when it was first finished in time for that important anniversary and I hope that once again we can call upon the help  of the OSS community .

Watch this space… ” Read more here

Rene EFE.

Follow the restoration thread here