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BadFoot Customs, Byram Cum Sutton (2026)

15/05/2026

Evening all, I've got a few repairs to share this evening.
First one is a set of exhaust headers for a Yamaha FZ1. The owner was unlucky whilst riding to have a brick bounce up and hit one of the down pipes.
Being stainless steel makes them a tough repair to remove the dents because you have to get the metal hotter and use a higher pressure to manipulate out the damage. On the plus side though they don't need rechrome afterwards and so can be finished off with a good polish.

Still on with the exhaust theme this next one is a pair of exhausts for a Suzuki GT125.
These had the usual dents and scrapes in various places but also most of the baffle chambers were either broken or mangled so a lot of work was required to repair the insides too. Add to this you can see from the photos the amount of carbon build up over the years which will strangle the engine performance.
The end result are a pair of pipes that will perform much better and chrome plating companies are unlikely to refuse plating these as they are completely clean inside so will not contaminate their plating tank.

The next repair is also for the GT125. This time the rear mudguard needed attention. Again it was quite beaten up with dents and cracks but also for some unknown reason someone had cut out a piece from the front end.

This mudguard is only 0.9mm thick so it takes time to butt weld a new section in place and blend in so the surface finish is flawless to the required standard for rechroming.

Last job is and aluminium oil filter housing I think is for a Yamaha XJ900. The local vapour blaster discovered a crack in the o ring seat.
This was very a delicate repair because I had to build up a 1.5mm thick "wall" and then re machine the radius for the O ring to seat in original position. This in itself creates a challenge because I need to ensure the housing sits concentric to the rotary table. So to do this i made a mandrel for the housing to fasten to then grip the mandrel in the rotary table chuck.

So what at first appears to be a simple welding job required much more work.

01/05/2026

Last couple of repairs I have to share tonight have something a little different from what normally appears in thw workshop for repair.
First one is a headlight bracket for a Suzuki GT500 that was badly beaten up. This received the usual amount of TLC to remove all the dents and get it to a standard suitable for rechroming.
The item that was out of the ordinary for me was 1986 Haro BMX frame saved from the scrap heap. It needed a bit of work to bring it back to usable condition. The seat tube was badly damaged and poorly repaired. The rear axle drop outs were worn and the brake cable guides were damaged plus a small dent in the lower tube.
So to sort this i replaced the seat tube and made a new gusset. The worn drop outs were welded then milled back to size and for the cable guides the owner gave me creative licence to make something different. I decided to make some little cylinders to resemble machine gun barrels for the finishing touch.

01/05/2026

Next lot of repairs I have to share tonight are a couple of frames and an exhaust.
The first frame is actually a modification as a repair prevention on a Triumph oil in frame, possibly a Bonneville. These suffer from the rear mudguard bracket cracking with then causes the oil to leak from.the reservoir. I made a couple of gussets then brazed them on to the weak area so should prevent a possible future failure.
The second frame is from a Kawasaki KDX 200 with some corrosion holes and a cracked engine guard.
Last of all is an FMF expansion chamber also for the KDX with a dent and a couple of small pin holes to rectify.

01/05/2026

Evening all, I've got lots to share tonight.
Firstly we have a couple of Yamaha RD cylinders with damaged exhaust studs and previous failed repairs. One is a YPVS and the other is a 4L0 LC but both have the same problems and required the same type of repair. Helicoil or thread inserts were out of the question as you can see from the before photos. The only option is to remove all the damage and start fresh with new metal welded on to build up thw area before machining back to factory condition.

12/04/2026

Next lot of repairs are a bit of a mixed bunch.
First off there are some rare Stainless steel exhaust link pipes for a Honda VTR SP1. These had suffered some road rash and were dented everywhere. Being thin Stainless steel made the repair more difficult as it's not an easy material to work with. There was a point where I nearly had the repairs completed but one particular area was full of stress fractures and nearly had me throw in the towel. I tried welding in a repair piece but the surrounding metal was too thin from the original bending process for me to get the mirror finish. I decided to put it down for a few days and order a small piece of pipe mandrel bent to the same specification. I then made a crude jig fixture then cut out the damage and welded in the new piece to exact same position. Then a polish and job done.

Next repair was fpr an Aprilia RS250 with a broken frame. The side stand mount had broken off so this needed cutting off and a new one fabricating.

Last of all is another 2 stroke legend, this time for a Suzuki RGV Gamma 500. The rear swing arm had seen better days and was covered in gouges and also some corrosion where various bracket were bolted on. These were all welded up and then hand filed back to the original shape of the extrusion.

12/04/2026

Evening all, hope everyone has has a nice easter break.
Back at work now and I thought I'd share some of the repairs from recently.
I'll start off with some Yamaha RD engine parts.
First one is a cylinder for an RD500. This one had been over ported to take bigger reed valves but the person doing the work went too far and broke through the side wall of the inlet port.
The whole side was as thin as tin foil so I had to thicken up the whole side to restore the structure of the port. Unfortunately the casting numbers were lost due to the amount of welding required but on the plus side it can now run with the oversized reeds.
The second job was on YPVS parts. The cylinders had the usual exhaust stud damage that had been poorly repaired and the lower engine case had some damage from the common chain failure.
Third job was a broken engine mount for a set of Triumph T120 cases. This received the usual treatment and is good as new.
All parts saved and back with their owners to live another day.

18/03/2026

Second job tonight was for a Yamaha RD case with some bad repairs. At some point in its life the chain had snapped and smashed the top cover and cracked the area around the gear lever. To gain access to fully weld and seal the cracks I had to cut up part of the case which is a daunting task in itself. It was the only way I could get close enough with the TIG torch. The welds on the previous repair weren't very good. You can see from the black discolouration after I milled off the welds where it was leaking oil and the top part of the case that had been re made just didn't look anything like the original shape. It was missing a few details like the ridge along the edge where it meets the side cover and also the little ramp that faces the direction of the drive chain. And they say the devil is in the detail so it was chopped off and re made correctly....

18/03/2026

Evening all, I've got a few repairs to share today.
First job is the third pipe out of a batch of Honda CR250 Elsinore I have been working on. Out of the three this one was the worst. There wasn't an area that didn't have dents in it so it was a full split down and repair job to get it back to original factory condition. Besides the dents I also had to replace the end pipe as it had been cut off some time long ago

All the dents were removed by old fashioned hammer and dolly work with a bit of English wheeling then fully welded back together.

26/02/2026

Evening all. Sorry its been a while since I posted any repairs, I'm battling through the massive pile of parts in need of rescue.
In the meantime I thought I'd share a few of them, it's a good selection tonight.....

First of all is we have a whole bike that came in for repair. This was a KTM 300 with a broken lug on the side of the cylinder for mounting the fuel injector. Normally I wouldn't carry out such a repair while the bike is built but on this occasion I made an exception as the access to the area was good.

Next job was a pair of cast iron Tiger Cub barrels with lots of broken fins. Not an easy task as the brazing procedure for cast iron involves pre heating and post heating as well as the actual brazing repair process.

Then we're on to some exhausts for a change. I've done expansion chambers for this make and model in the past ( 1975 Honda CR125 and 250 Elsinore) so it was familiar territory. I managed to repair these two without completely splitting them open but due to the amount of dents in them it was still a very lengthy process. Both needed a fair amount of fabrication, the 125 pipe needed a new silencer making from scratch as the original was rotten. The 250 pipe had a completely wrong silencer welded on the end so that needed cutting off and the exit pipe making back to original as it left the factory. Besides all this there were the multitude of dents, scrapes and holes to repair.

Last of all its back on to cooling fin repairs for a Yamaha RD400 head.

Coming up next week will be number 3 of the Elsinore pipes, this one looks like its been run over by a bus! Stay tuned....

31/01/2026

Next job I have e to share is a custom headlight assembly. The bike is a heavily modified Triumph Thunderbird with a custom set of yokes, wider wheels ect so the customer ask if I could make a headlight unit to fit a later model Triumph headlight from a Truxton and keep with the chuncky fatboy style. This was quite a large amount of work as I have never made a headlight so I had to make all the tooling to roll the light retaining bezel and then make the tools to mark out the radius flat pattern to roll a truncated cone to specific dimensions for the light unit to fit inside.
This is all made from 2mm aluminium flat sheet with fabicated 10mm thick fixing bracket.

In the near future I will also be making him a custom front mudguard and set of handle bars

31/01/2026

Next two repairs job I have to share are a Suzuki A100 with a damaged worn out exhaust thread and a Yamaha DT125 side case with a hole near the kick start shaft.

The best option for the A100 thread was to completely cut it off and make a new one then weld on and blend in.
The DT case was a straight forward weld in a new piece then blend in.

BadFoot Customs

15/05/2026

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12/04/2026

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