View Full Version : Bike Build: "Azrael" by Urban Assault

01-25-2010, 09:47 PM
Not much to show yet, just a sketch of what I had in mind.

A little hard to see, but I'm basically going to fab a new airbox cover out of steel, so it looks like a ribcage

The seat will be a bare-bones metal seat pan, sort of like the metal seats on an old-fashioned farm tractor. Absolutely nothing behind it except the rear wheel.

The airbox will have a "spine" going down the center and attaching to the seat, which should sort of resemble the pelvic bones in a skeleton.

Everything will be blacked out, and I might do some subtle chrome accents on black wheels, sort of like beadlock studs.

I've got some other "goodies" planned, too. Since you'll be able to see into the airbox through the "ribcage", I'm going to fab a custom intake, air filter, exhaust valve, etc.. so they look like organs, then light it with a pulsing red LED to simulate a heartbeat.

I'll have to relocate the battery and electronics from under the seat, still tossing around some ideas on that.

All kinds of crazy stuff floating around in my head... Now, if I can only get some of these ideas to actually work!

It'll be a slow build, due to limited finances and an upcoming move, but wanted to get some feedback as the project gets rolling.

Stay tuned...



01-25-2010, 09:54 PM
This is sort of what I envision the "tail" to look like, but obviously very different.

Basically, a solo seat with nothing else behind it. I'll probably integrate the stop/turn lights into the underside of the seat somehow.


01-25-2010, 10:10 PM
Hope it turns out. I like where you're going with it. Are you making this stuff yourself? Are you going to cast this or pound out the metal to form?

Give us pictures on your progress.

01-25-2010, 10:16 PM
Will definitely start posting pics. It'll be mostly hand-formed, torch-and-hammer style. I want it to look crude and rugged, the kind of bike you'd run from in a dark alley... not something I spend 10 hours a day polishing to "look pretty".

I think it fits the Buell's attitude a little better.

I might toy with the exhaust, too. Got some ideas there.

01-25-2010, 10:36 PM

i think its going to be one sick ride [up]

01-25-2010, 11:01 PM
nice idea [up]
look forward to seeing your progress :)

01-25-2010, 11:03 PM
[up]Definitely get pics of some more sketch work. Sounds like a demented build for sure. GO FOR IT!

01-27-2010, 07:51 PM
Where you plan on relocating the battery and electronics to?

01-28-2010, 02:33 AM
The electronics should not be too much trouble. I'm going to unravel the wiring harness, separate everything, and tuck them up into whatever nooks and crannies I can find.

The battery will suck, no doubt. I've got a couple of ideas on that.

One is to run four small 6 volt batteries spread out in various locations on the bike. I can wire two each in series to bump up to 12v, then wire the two "duals" in parallel to up the amperage. It'll be tough finding smaller batteries that can handle that much current draw, but I'll tinker with a few test batteries and hope they don't explode.

The other option is a bit more complicated, but way more bad-ass... I can get rid of the starter altogether and convert the motor to a kick-starter. That would allow me to run an extremely small battery, and just run the lights/accessories off the charging system.

Unfortunately, no one makes a kick-start "kit", so that's going to take a lot of fabrication... I'm really hoping the battery idea pans out.


01-28-2010, 02:58 AM
kick start would be a sick addition to that design

01-28-2010, 07:52 AM
You could put the battery under the bike like this....

might work???

I like the seat also

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Johny Kidd
01-28-2010, 02:08 PM
Something like this?


01-28-2010, 02:29 PM
if you fab a kick start kit I want one too

01-28-2010, 02:46 PM
Someone mentioned putting the battery underneath, but I'm extremely hesitant to do that.

There will be a lot of heat from the exhaust, even thought the outlets are angled away. Also, the shockwaves from the exhaust tone will cause serious internal vibration through the liquid. The lead cells are pretty fragile, so I expect the battery would become toast after only a few longer rides.

Johny Kidd - That's closer to what I had in mind, but this build will be even more stripped down.

01-28-2010, 03:05 PM
Can't wait ,sounds really cool http://www.mysmiley.net/imgs/smile/evilgrin/evilgrin0023.gif

Evil Mechanic
01-29-2010, 02:44 PM
You have some cool ideas man. What are you gonna do for a headlight?

01-29-2010, 03:57 PM
I'm still deciding on the headlight, too. I thought about removing the whole headlight assembly and going with a "dirtbike" look on the front end. For lighting, I would use a few dozen of the 1-watt high-intensity LEDs mounted on a dirtbike "number plate". Definitely not DOT approved, but should give enough lighting for cruising around.

I'm also looking at using a raw/naked 2004 GSXR headlight (without the fairing). By itself, it's got kind of an evil "gas mask" look to it.

Found my seat... This is probably the style I'll go with...


01-29-2010, 04:12 PM
Like the seat... And as for the gsxr headlight I have seen a few done as fighter headlights and they to look wicked clean! Goodluck on on the build!

01-29-2010, 06:29 PM
totally awesome.. and i def agree, stripped down and rugged goes more with the buell's attitude.. exactly what i want with my bike.

Johny Kidd
01-29-2010, 06:43 PM
Iron Butt! [cool]

02-22-2010, 05:38 PM
Found this seat on eBay last week. I have no idea what it's from, but it's freakin' perfect for what it's going on!

Surprisingly comfortable for a seat with no padding.

Just came in the mail today. There are a few cracks I'll have to weld up, and I've got to fab some mounting brackets. Just waiting for the snow to melt so I can fire up the welder.


02-22-2010, 05:50 PM
neat build. as far as batteries go I have heard about some batteries that Erikbuellracing is going to be selling soon that will be a lot smaller and lighter than the stock batteries maybe they would be something easier to hide or stuff some were.

02-22-2010, 06:23 PM
this is the batery you need they cost alot but save alot of space check out the video


02-22-2010, 06:26 PM
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02-22-2010, 07:48 PM
try this one,,,[up]

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02-22-2010, 10:27 PM
Thanks for the info, guys. Think I've got the battery situation figured out. [up] Those from TekBattery.com are really sick, but like you said... pricey. Hard to swallow, but I might spend $1000 on a battery!

Here's a few pics of the bike as she sits now. Hopefully I'll be able to show you all some progress in the next couple of weeks.


02-23-2010, 01:51 AM
i have no idea how to post videos lol.

02-25-2010, 10:30 PM
Got a chance to move the beast out the barn, and start on some welding! Woo-hoo!

Fixed the seat, and finished up the main "spine" assembly. Still need to do the ribcage, but I'm going to do the seat brackets first.

Turns out cast iron is a bitch to weld. If you don't pre-heat it with a torch, the welds will crack when they cool. You also have to let it cool slowly, using the torch to keep it warm for several minutes. Finally got it, though.


Excuse the coconuts... I was trying to get a feel for what it will look like once the seat is on. It's going to be tough to keep a comfortable seating position, and still maintain the lines I want. I'll probably build an adjustable seat bracket so I can still mess with it once it's done. That'll also help in case someone tall ever rides it.


This shot gives you a good idea of how the "spine" flows. It follows pretty close to the stock airbox cover, with just a slightly more aggressive hump. I thought about using clip-ons, but don't think I'll be able to do it. It would look bad-ass, but I probably won't be able to reach the handlebars if I do... We'll see.


A couple more pics showing off the new spine and ass-pan:




And... Just because I can:

02-25-2010, 11:09 PM
is the cast iron just a mockup, or is that what your going to use?. btw that seat looks like it would be comfortable ,wouldnt want my junk so close to the spring tho lol. those bumps are a mofo..... o btw have fun rewiring the harness, i did it to my fire bolt moved everything under the tank ,but it got to hot then i moved it under the seat

02-25-2010, 11:25 PM
That's the seat I'll be using. When I build the brackets, it will sit a little higher up and angled back. I want the curve of the spine to flow right into the seat.

02-25-2010, 11:31 PM
o i.c . any ideas on the harness tho. you can build a little battery box sorta thing under the seat and have the tail light sitting in front of it, that might work

02-27-2010, 12:11 AM
I want to keep as much of the wiring and stuff in the frame/airbox as I can. I don't want anything behind the frame except the seat itself.

Got a chance to work on it some more today. Finished up the new subframe, and started working on re-wiring the harness.


Woo-Hoo! No more coconuts holding the seat up!



The seating position is actually WAY better than I expected! It's maybe a half inch or so lower than stock, and still fairly comfortable.

The seat looks a little bulky-er than I had hoped. I may trim it down later, but for now I want to finish everything else. I think once I finish the ribcage, the wider top will help it look more balanced front-to-rear.

I think the seat just sticks out visually because it's the only thing there right now.



I'm going to do the wiring before I finish the ribcage, just so I don't have to keep putting on/taking off the subframe while I'm working on it.

I had to lift the bike off the ground, so I could remove the rear shock. That let me remove the cooling fan, which gave me access to the wiring harness.



I was hoping I could split the two fuze-box sections and feed them through the hole in the frame on the left side, but no such luck.

I'm going to have to remove the wires one-by-one from the fuze box, and feed them up through the frame.

Arrgh!!! Not looking forward to this part... I may try to just disconnect the motor mounts and rotate it forward to see if I can squeeze it through that way.


02-27-2010, 12:44 AM
How in the hell are you going to put gas in it at a gas station?

02-27-2010, 12:48 AM
so are you going to run it over the top of the frame and stick it in the air intake hole from the top, or are you going to run it along side the engine and stick the fuse box from underneath. the only problem i.c with running the wires along the motor is the heat cus buells are moving space heaters you know. another idea you can do is shorten the wires and make a square hole in the air filter housing toward the very back of it so you wont even see the fusebox untill you take off the air cover. another thing whats going to be your rib cage spacing .

02-27-2010, 12:56 AM
just got a idea you should use this as a head light then you can call your bike (The Bull, or FireBull, or Raging bull)http://www.buellxb.com/buell_images/1582_20100226185427_L.jpg

02-27-2010, 01:13 AM
How in the hell are you going to put gas in it at a gas station?

Haha... There's just enough space, but not much to spare.

Not sure on the ribcage spacing yet. It'll be more rebar, but I'll play around with spacing before I decide for sure.

As for the heat: The wires are already running through that part of the frame, I'm just having them exit through a different hole.

02-27-2010, 01:18 AM
thats one big head ache reversing them ,lots and lots of shortening and lengthening, if you plan on using that plastic wire insulator mounted on the inner frame. like i said in a earlier post i reversed my wire harness b4 and i ran them thru the intake hole , took me a good 3-4 hours to do that . cant wait wait to see that ribcage on tho, keep up the good work man.

02-27-2010, 01:54 AM
That's going to look absolutely WICKED once you're done. I never would have thought of using rebar for a bike. VERY unique![up]

02-27-2010, 08:21 PM
A bike even ghostrider would be proud of

02-27-2010, 08:59 PM
Thanks guys, I appreciate the support. Quite honestly, yesterday, I had the "WTF was I thinking?!?!?!" moment...

Today, however, was a new day. I decided to drop the motor instead of re-working the harness, it ended up being a VERY good choice. I used the "engine rotation" procedures(thanks Buelltech!), and it went very smoothly. Had the motor dropped in about an hour.

Here's the motor almost out:


That gave me just enough room to move the harness up through the main airbox opening. I wound the wires with a good quality heat tape, which should protect them (supposedly) up to 1500 degrees.


This is where my wife walked in. She was smiling, getting ready to tell me something happy.... Then she saw the bike. She got a very concerned look on her face, then turned, and walked back into the house without saying a word...


So here's where we leave off today.

Since I had the motor most of the way out, I decided to throw a coat of flat black on it. I'll eventually have it powdercoated, but for now I'm on a time-crunch. Hoping to have the bike rideable for the St. Patty's Day parade in two weeks.

I'll put a fresh coat on the exhaust too, since that's off the bike now anyways.

You can see the rear looks much cleaner now, no wires hanging out where the seat will be.

Won't have much time to work on it until Wed/Thurs, so wish me luck. St. Patty's Day is right around the corner!


03-06-2010, 04:17 AM
Finished the "Ribcage" last night, turned out pretty decent. Definitely balances the seat a little better.

I'm probably going to go with a dark grey instead of flat black, I want this to stand out a little more.

Still need to clean up the wiring, and build a mount for the battery. I found a really small battery that I can tuck up next to the air filter, I'm just worried if it'll have enough juice to turn the motor. I'm charging it up now, will hopefully test it tomorrow.

Also going to black out the air filter. Hoping to have it mostly done this weekend.





03-06-2010, 10:19 AM
I like, can't wait to see the finished product. Where can I find those handguards?

03-06-2010, 12:13 PM
I think it's going to look great when you're done. Have you tried sitting on that seat while it's on the bike? While it looks like it has a nice bucket shape to sit in, I feel like it might be hard to get your feet right under you to the foot pegs with the shape of the seat. It seems like the kind of seat that would be better suited to having foot pegs a bit more forward.

03-06-2010, 12:47 PM
I think the rib cage air box looks really sweet I just do not like the tractor seats on bikes. Heck that is the one thing I hate about confederate bikes.

03-06-2010, 01:33 PM
Love the progress I'm guessing fair weather only though

03-06-2010, 04:22 PM
That rib cage is looking sick keep up the good work

03-06-2010, 04:26 PM
The seat is actually very comfortable in the riding position. The only time it's not is when I put my feet down at a stop, the edge kind of digs into the back of my thigh. That's really just because I have short legs.

The seat mount is adjustable, so I can move it back about 4-5" for taller riders.

As for being fair-weather... Yeah, I've been thinking about that. I'll probably silicone all of the connections and waterproof the fuse box as best I can. Down the road, I may fab a cover that goes over all of the electrical stuff. But for now, I just want to get the damn thing running.


03-06-2010, 04:33 PM
What kind of air filter is that and how did you get it hooked up? That looks sweet!

03-07-2010, 01:58 AM
It's actually just a cheap filter I picked up at AutoZone for $20. Needed something on there when I fire it up, but I might stick with it.

No special mounting required. Once you remove the old air filter, take off the stock rubber velocity stack. You can stuff the stack through the bottom of the air filter, then tighten the hose clamp on the air filter.


03-07-2010, 10:32 AM
Dude, That would look sick with the red translucent plastics underneath the rib cage. It would also solve the fair weather only ride.

03-07-2010, 08:10 PM
Interesting idea, I might try that out. I don't think they'll both fit at the same time, but maybe with some trimming...

Oh, and sorry I missed your question about the handguards - They're actually ATV hand guards made by Kolpin. You can find them for about $30, and I'm really happy with them. They have integrated mirrors already, so I could ditch the mirrors altogether and still be legal.

Evil Mechanic
03-18-2010, 06:16 PM
God im so glad my wire tucking nightmares are over! I feel for ya mang :p

03-18-2010, 08:15 PM
any new pics urban?

DrogeN Omen
03-24-2010, 12:52 AM
All i can say is... Damn...

'Urban' that is gona be one sick looking bike when its done.

what are you gona use to cover the air filter?

are you gona use a clear plastic cover under the rib cage?

cant wait to see the finished product.

03-24-2010, 01:02 AM
Hey urban does that filter setup kinda mimic the fast intake?

04-09-2010, 05:19 AM
hows the build goin???

04-12-2010, 06:04 PM
Hey guys, it's been a while since I messed with it.

Went out to the barn a few weeks ago, found out that mice had chewed the wiring. I was so pissed, I didn't even want to look at the bike anymore. Totally lost momentum on the project.

I moved the bike back to the garage last week, and dropped the motor again to inspect the damage.

Luckily, the mice only ate through the wrap, not any of the actual wires. WHEW!!!!

Should get some more funds in the next week or two, so hopefully I'll get some more progress for you guys.

As for the intake filter, it's actually pretty small. I tried the FAST filter, but it wouldn't fit under the ribcage. This was the only other one I could find. I'm a little worried that it might be too small, and not have enough airflow, but I'll do some datalogging after its all back together and find out.


04-12-2010, 06:07 PM
Another question about the filter... is the velocity stack shoved inside of it or did you remove it?

04-12-2010, 06:10 PM
The velocity stack is inside. It's tough to stuff it in there, but once it's in it actually fits perfectly. You can just tighten the clamp around it, and it makes a pretty good seal.

04-13-2010, 07:15 AM
Well that is cool.

Pimp my RIDE (http://poorboyspost.com/ebay)

04-17-2010, 03:52 AM
Finally got it running today, Woohoo!

Finished the battery tray, and mounted most of the electronics. Swapped the silver air filter for a red one, looks MUCH better. Blacked out the chrome parts, so it blends in better with the bike.

I got a small matching red breather filter, and used that to cover the air sensor. Wasn't sure if it would work being outside the main air filter, but it seemed to run fine. I actually think the bike is running a little cooler now that the heat from the motor isn't trapped under the airbox between the frame.

Took it out for the first ride to run some errands, and put about 60 miles on her. WOW does this thing get attention! Had a few people take pics/videos driving down the road, and had someone come up and ask about it at almost every stop.

For anyone curious about the filter: The smaller filter seems to be running fine, just takes a little getting used to the "whoosh" noise from the airflow every time you open the throttle. If you're still running your stock translucent cover, you probably won't hear it like I do.

I still need to clean up the wiring, find a good place to mount the license plate, and get something better for the tail/brake light. (Right now I'm just using an LED pod zip-tied to the back of the seat :D )

Definitely has a rat-rod look/feel to it.

The seat is surprisingly comfortable. The position is pretty far back, so I do have to reach a bit for the handlebars.

And yes... I finally removed the warning sticker. Didn't notice it there until I took these pics with my cell phone. I'll get some better pics and close-ups of the airbox area when I find the real camera.



04-17-2010, 08:07 PM
Just a thought... but you should repaint the spring to match your wheels and air filter :) all in all though that is a bada$$ bike!

04-17-2010, 09:53 PM
Yeah, that yellow spring is an eye-sore. If I can find paint to match, that'll be the next thing I do.


04-17-2010, 09:54 PM
OMG I would be so scared of pinching my junk in that spring. Not my cup of tea, but to each his own.

04-17-2010, 10:39 PM
defiantly interesting and very cool! Mad skills man. Can't wait till you get to do some data logging with the filter![up] Your rep point should multiply like bunny wabbits for this one!

04-18-2010, 01:26 AM
also... i think it would look nice if you could give the chin fairibg a similar look and maybe the ully fork guards/fender, and minus the belt guards... just my 2 cents worth still amazing

04-18-2010, 05:21 AM
Thanks. I was thinking along the same lines on the front, using fork guards and a different fender. Will probably get the headlight guard, too.

I've got some ideas for the chin/muffler, but not sure if I want to open that can of worms just yet.

04-18-2010, 05:48 AM
where is the battery? I dont see it in the pic..

Also all looks great IMO you should brng the seat tray up a bit to give it some angle instead of the flat line[smirk]

Looks crazy though, would hate to hit anything on that specially my junk.:p

04-18-2010, 07:21 AM
its still missing something, im not quite sure what it is but. id say make the front fender like the rib cage and do something with the fly screen in iron . also maby make some lense covers that look like iron mans eyes that would look sick as hell and let the ****er rust.

04-18-2010, 08:47 AM
It might look better if you had the rebar go all the way down to the top of the frame, just seems like too big of a void.

04-18-2010, 05:59 PM
A TRUE Naked Bike :) I love the creativity. [up]
would be nice to have a pic of someone sitting on it to see what it looks like when its being ridden

04-18-2010, 08:04 PM
Thanks... I've gotten a mixed response on different forums, seems like you either love it or you hate it.

The battery is mounted on the left side of the air filter. I found a battery that's about half the size of the stock battery, but has just enough power to crank the motor.

A few people mentioned getting your "junk" caught in the spring, but luckily the seat has a built in nut-cup that keeps your goods from hanging down and getting squished like grapes.

A little hard to see in the pics, but it comes up in front of the seat, and flows with the lines of the spine where it ends.

DrogeN Omen
04-18-2010, 09:42 PM
what are you going to use to cover the air filter, battery and wires from the rain???

you going to try and mold a clear/translucent tank to fit under the rib cage???

how about posting some closeup pics of the seat and air filter area so we can get a better idea of how and where everything fits in...

04-18-2010, 09:59 PM
I'm just leaving it open. Not too concerned about rain, as we don't get much here in Colorado. Like I said, just checking the weather and crossing my fingers before each ride.

I'll post more pics later this week when I get my camera back... The wife took it with her to South Carolina.

04-22-2010, 03:41 PM
Dude, Urban...wow. This is really turning out awesome! I'd definitely build your own headlight grill with some smaller rebar and do a bare metal front fender.

04-22-2010, 03:48 PM
+1000 on not wanting my junk in close proximity to the spring!

BTW that's my cats name.

05-09-2010, 10:35 PM
Here a few pics of me on it, so you have an idea of the seating position. Like I said, surprisingly comfortable.

Still feels really solid through the corners, but it does take a little getting used-to.

I need to clean up the wiring, mount the tail-light, and probably find a better way to mount the license plate.

I'be been giving some thought to the front end, and I think I know what I'm going to do now... Someone made a comment about it being a "true naked bike", and I think I'm going to run with that.

I'll probably strip the whole headlight assembly and instrument cluster completely off, leaving just the forks. I'm thinking I'll mount a small HID light just above the front fender.

I'll pull it apart and stare at it for a few days before I decide for sure.





07-06-2010, 07:18 PM
Any updates?

07-14-2010, 04:24 PM
How about the digital unit for your triple? No gauges needed then. A low mounted HID would be a good choice.

07-14-2010, 07:05 PM
Any updates?

Doubt he's doing to much more stuff to it since it's For Sale (http://www.buellxb.com/Buells-for-Sale/Buell-Lightnings-for-Sale/2008-XB12Scg-1)

06-18-2011, 05:31 AM
how hard was it to rewire everything?
and where did you find that seat its super sweet

10-03-2011, 06:17 PM
Hey pamver,

Sorry for the late response. Haven't ridden in almost a year, so haven't had much time to check the boards here.

I got the seat on eBay, just an old tractor seat from the 1900-1920's.

I'm actually going back to an "R" tail soon. Re-wiring was a total pain, so not looking forward to putting it all back.

10-03-2011, 06:32 PM
Man looked sweet!!! if you are in need of an R tail I have one though?

10-03-2011, 07:21 PM
Thanks Kuntreeboy. I've had one sitting in the garage for a few months now, just haven't had time to put it on. It'll be (another) one of my winter projects.

10-07-2011, 03:52 PM
Nice boots! standard issue I presume? :D

10-08-2011, 08:02 PM
Haha, yeah. I've got about 5 pairs now, gotta do something with 'em!

10-10-2011, 11:20 AM
I wear my SI boots for riding too! Nice bike too, once I get to Germany I want to start building up mine since I heard riding over there can be a pain.

10-10-2011, 11:25 AM
I've got about 5 pairs now, gotta do something with 'em

Ebay is your friend on that, I had 3 extra new pairs when I got out, sold each pr for $75 a pop. Not bad considering I got them for free [up].

10-10-2011, 11:30 AM
The only thing that sometimes sucks is that they are a dead giveaway that you are a soldier, especially in a military area.

10-11-2011, 02:53 PM
There are 5 (yes, FIVE!) military bases in Colorado Springs...

If you're not a dirty hippie, it's just assumed that you're military.

lightning SS
01-10-2012, 09:00 AM

01-23-2012, 02:24 AM
Very different.

02-15-2012, 12:22 PM
Thanks guys. Been out of the loop, haven't even ridden in over a year. :(

Finally ordered the parts to put the "S" tail back on, so I've got an extra "R" I'll be selling. If anyone wants this crazy rebar-skeleton thing, it's all yours. Let me know.

02-15-2012, 05:36 PM
There are 5 (yes, FIVE!) military bases in Colorado Springs...

If you're not a dirty hippie, it's just assumed that you're military.

I knew that something looked familiar about the back ground in those pics. Im from the Springs. But Am now in the St Louis Area. Bought my first Buell (S1) from
Pikes Peak HD. My Brother still lives out there in Black forest, and is looking for a Buell. Hope to be back there soon. Loved the riding up to Cripple creek, and beyond.