Honda Hornet - blabla - něco úderného!

Overview

Biker Boys Garage visits Westwerk Plzeň to view a custom Honda Hornet built to order for a friend. The bike won a prize at the first Classic Bikefest in Varsdorf. Cold weather pushed filming inside the Westwerk workshop, where the crew walked through the build details.

Styling concept

“Old tank on a modern motorcycle” — a vintage CB-style tank married to a modern Hornet frame, producing a minimal, industrial look (metal seat tail with rivets/dimples).

Highlights:

• Metallic/pearl paint finish salvaged from a purchased tank; sunlight creates striking reflections.
• Hand-formed sheet-metal rear tail (not fiberglass) for a raw, durable aesthetic.
• Many bespoke and CNC-fabricated parts to blend vintage and modern elements.

Key build details

Frame and chassis

• Chassis largely original: swingarm and central shock mount left stock to retain handling characteristics.
• Significant frame/tank interfacing work: the bottom of the vintage tank was reshaped to fit the Hornet’s square frame — required cutting, forming and welding to achieve minimal gaps.

Tank and fuel system

• Tank restoration: a cracked/wrinkled vintage CB tank was reshaped and welded back into form by tinsmith Radek Krchmanů (Protivín).
• Because reshaping the tank removed internal space, the build uses two external fuel reservoirs; fuel plumbing routed accordingly.

Fabrication and bespoke parts

• Custom upper triple clamp and mounts (CNC-machined).
• PP Tuning handlebars and stainless braided brake lines.
• Recessed, homemade headlight mount to accept a large round lamp.
• Hand-formed, welded sheet-metal tail section with visible rivets/dimples for the industrial look.
• External fuel reservoirs fabricated and integrated.

Electronics and lighting

• Moto Gadget electronics: RFID immobilizer, display cluster, and indicators (Daytona / Moto Gadget instruments referenced).
• Kellermann homologated tail light and LED signals — three-lamp setup for improved visibility and legal compliance.

Engine and drivetrain

• Donor engine: original carbureted Honda Hornet engine retained (repainted and tuned).
• Carburetor tuning performed on a dyno/brake by Robert Johaník (Koterov) to match the new intake and exhaust.
• Custom short twin exhausts deliver a deep, pleasant sound.
• The bike is road-legal and regularly ridden, not just a showpiece.
• Possible future idea: swap to a touring Hornet engine variant (all-black finish) for aesthetic refinement.

Practical tips and recommended steps from the build

• Collaborate closely with the owner; iterate on colors and seat/tail design together.
• Prototype and test fittings (3D checks / mockups) before final fabrication.
• Use CNC machining for precision parts (upper clamps, brackets).
• Repair and repurpose quality vintage parts (e.g., CB tank) via skilled tinsmithing rather than discarding.
• Expect to cut, re-form and weld tank bottoms to mate vintage tanks to modern frames.
• If tank reshaping removes internal fuel space, plan for external reservoirs and safe fuel routing.
• Keep homologation and safety in mind: use certified lights/signals and ensure visibility.
• For carbureted engines, retune on a dyno/brake after intake/exhaust modifications.
• Use robust metal fabrication (sheet-metal forming, reinforcements) to keep the industrial look durable and road-worthy.

Notable locations, people and products

• Locations/events: Westwerk Plzeň (workshop), Western Bohemia, Classic Bikefest in Varsdorf.
• People: Pepa and Lukáš (Westwerk/build team), Radek Krchmanů (Protivín tinsmith), Robert Johaník (Koterov — dyno/brake tuning), the owner (client), Biker Boys Garage hosts.
• Products/brands/components: Honda Hornet donor, vintage Honda CB 500 tank, PP Tuning handlebars, Moto Gadget / Daytona electronics, Kellermann tail light, stainless braided lines, CNC-machined parts.
• Channel/platform: Biker Boys Garage (YouTube); additional content on HeroHero.

Outcome

A functional, rideable custom Hornet that blends vintage styling with modern performance and safety — award-winning at Classic Bikefest and built to be used regularly on the road.