BadFoot Customs

BadFoot Customs Vehicle Component Restoration and Customisation

Last job is have to share tonight are a some engine cases and centre stand for a Suzuki MD50.One of the engine cases had...
03/08/2026

Last job is have to share tonight are a some engine cases and centre stand for a Suzuki MD50.
One of the engine cases had a busted main bearing seat and the other side had a damaged oil seal seat.
These type of repairs are very labour intensive as the measurements need to be critical so a lot of time was taken to measuring before going at it with the TIG welder. Not only was the fl**ge broken off but also the journal was gouged from pressing in the bearing at an angle.
The entire bearing journal and oil seal seat had to be reconstructed and bored back to spec.
The second job was to make some new feet for the centre stand. The original one were worn away.

Here's a little update on a Suzuki PE250 exhaust I repaired a few weeks ago. I had to hydroform a new primary section an...
03/08/2026

Here's a little update on a Suzuki PE250 exhaust I repaired a few weeks ago. I had to hydroform a new primary section and remove all the dents.
The customer has painted it and now back on the bike

Here are a couple of custom jobs for a change.First is a headset made to attach a set of Harley Davidson Fat bars to a V...
03/08/2026

Here are a couple of custom jobs for a change.
First is a headset made to attach a set of Harley Davidson Fat bars to a Vespa scooter!
Besides making the headset I also had to modify the Harley bars to take the smaller diameter hand controls.

Second job is a pair of torque arms for a brake plate out of aluminium.

Evening all, yet another exhaust repair to share. This time off a 1985 FZ750 It looked like someone had run over it wit...
03/08/2026

Evening all, yet another exhaust repair to share. This time off a 1985 FZ750
It looked like someone had run over it with a bus. Then reversed back over it!
At the time I thought this is beyond repair as the design of these are very difficult to open up without causing even more damage and so more work to put right. Before starting on this I advised the customer it would probably be cheaper to get a set of reproduction exhausts but he said they just aren't as good and not accurate.
So reluctantly I set to it and drilled out the 19 spot welds, 4 pop rivets cut off the feed pipe and hanger till I had it in almost its constituent parts. This was then beaten in to shape with hammer and dolly then wheeled to get it smooth. After that it was in the slip rolls to make it cylindrical again after sorting out the road rash.
Finally it was reconstructed with the original baffles which actually were in good condition ( rare for a 4 stroke exhaust) welded and the end cap riveted back on.

What a marathon this was!

Here are a few random photos from the sissy bar fabrication off the Fantic Chopper. I also had to do a repair on the low...
22/07/2026

Here are a few random photos from the sissy bar fabrication off the Fantic Chopper. I also had to do a repair on the lower section of the frame. At some point in its life it had suffered a bad impact underneath crushing one of the tubes.
I came up with an ingenious way to fit the inner strengthening bars when welding in the new tube section. I used a sort of sliding door bolt design to move the inserts to position when the tube was in place. This then locked it all together adding strength to the weld area.

Evening all, back on with an exhaust. This time its off a Suzuki PE250.It was in a sorry state from old repairs, dents a...
22/07/2026

Evening all, back on with an exhaust. This time its off a Suzuki PE250.
It was in a sorry state from old repairs, dents and a split seam.
It was really bad on the header section due to the metal being very thin ( around 0.6mm) so the best option was to hydroform a new piece. This process take a fair bit of time to get right because you can't calculate exactly where it will expand and bend when making curves with changing radius and diameter. In other words its an educated guess for the initial patern shape and then work with what you got.
Fortunately it came out very close and so was possible to finish off manually with hammer and formers after the hydro forming.
Once this piece was completed and welded in place I had to get out the dents and finish off the repair of the other bad areas.
End result was a good sound leak free very rare expansion chamber saved.

16/07/2026

Sissy bar done.....

15/07/2026

I'm lost for words.....
I don't think I'll even attempt to repair this sissy bar 🙄

Next repair I have are a pair of Douglas heads. These engines have a weakness on the cylinder fl**ges. They break off w...
07/07/2026

Next repair I have are a pair of Douglas heads. These engines have a weakness on the cylinder fl**ges. They break off where the head is bolted on. One solution was to use extra long studs to clamp the cylinder in place rather than the heads being attached with captive studs. This means though the head studs need to be drilled right through and some of the cooling fins are lost near the bolt holes.
These heads were already modified in the bikes long distant past along with many broken fins. I was asked to make the heads look good again which involved creating fins that were never there and make it look factory while still allowing clearance around the head bolts.
I also had to make a bespoke cutting tool to machine the head bolt nut seating face as it was impossible to machine it using a conventional method because the rocker cover fl**ge is in the way
All in all it turned out well despite the alloy being awful to weld as it was full of casting impurities and porosity.

Next repair I have to share is a lower engine case for a Honda CB400 4. This one belongs to an old friend of mine, he no...
07/07/2026

Next repair I have to share is a lower engine case for a Honda CB400 4. This one belongs to an old friend of mine, he noticed an oil leak around the oil drain plug an discovered it had previously been repaired badly. A temporary fix was attempted with JB weld but was a wasted effort.
When I got to have a close look I noticed a crack going right through the threads and oil galleries so it wasn't going to be an easy fix. I had to mill off most of the drain area to get to the root of the cracks with then of course means more work to rebuild and re machine the area.
The sump plug was also a bit chewed up from years of use so I tidied that up on the mill at the same time.

The second job was a broken kick start stop on the engine case of a Yamaha RD engine case. This had a deep crack going through the stop and if left alone it would have broken off inside the engine with disastrous consequences.

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Byram Cum Sutton
WF11

Telephone

07542278116

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