Rebuilt 200cc motor. Replaced piston and rings. Polished gasket surfaces and brushed internal components. Coated the exterior casting with GunKoteā„¢. Reassembled with New-Old Stock (NOS) OEM gaskets.
Cut and welded frame. Welds we ground down and sanded smooth. Solid plugs were used to not only weld to, but also used to reinforce the seam.
Fabricated frame and mounted gas tank from a 1979 Honda CB400 Hawk.
CNC machined 7075 Aluminum billet.
Triple-tree CAD was created in SolidWorks.
Triple-tree assembly. New-Old-Stock OEM bearings.
Honda XL200 Restore/Fabrication

Progress of fabricating/restoring a 1983 Honda XL200R into a street tracker. Rebuilt motor, modified frame and machined a custom triple-tree assembly.

Todd Mendoza
Senior Innovation Prototyper at REI Seattle, WA