Summary of "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.