Scrolling through eBay, Facebook Marketplace and a host of other classified websites, you’ll quickly come across a host of custom project bikes that are “90% complete”. The reality is that very few are even remotely close to being finished and perhaps we have to take some blame. What we show you are the brilliant end products which have been pieced together by the best builders in the world. So, today’s tale is a two-for-one, as not only do you get pictures and the story of a stunning bike built by one of the world’s best, but there is also a comprehensive YouTube build series for you to both enjoy and learn from. The builder is Rob Chappell, his workshop is Canada’s Origin8or Custom Cycles Co. and what he’s created is this stunning 2008 Ducati S2R 1000.
The story of this build started when an American customer contacted Rob about adding a 749 fuel tank to his Ducati S2R and also crafting a new subframe for the bike. It seemed simple enough, until said bike arrived at Origin8or HQ on the back of a trailer, looking like it had been pulled from a lake. “Not only was it filthy but the wiring harness was severed, the original frame was already cut and the forks were both leaking, with bins of original parts already off the bike. Apparently, another shop had the build but after three years of it sitting in a corner the customer collected it back,” Rob explains. So, a new budget was discussed and the build time was extended to really do it justice.
To truly understand what he was working with, Rob began to sort the wiring out so he could see if the bike would fire up. “While I was busy trying to wire the bike up and see if I could get it to turn over, the client began sending images of BMW K100 Bricks that he absolutely loved.” Rob could see where this was going, the client wanted to use a K fuel tank on the bike and Rob explained how hard it would be to achieve given its dimensions and the Ducati frame, but after much back and forth, he gave in. This is where the build series on YouTube kicks off (link below) and not only do you get to learn from a great builder, but you truly get an insight into everything you’ll have to do and overcome should you take on a complete custom build of your own.
Having sourced the big BMW tank, Rob cut the base out, which allowed him to place it over the Ducati’s frame, and sent pictures to the owner. He loved the look! But first Rob had to switch his attention to another build and the time away from the S2R allowed him to come up with a great plan. To make the BMW tank work and still achieve the lines he was after, he built a custom fuel cell to go below the shell. Building this piece also meant that there would be extra room for the big pod filters and the stock Ducati sending unit was retained. “I ended up using very little from the BMW tank. It was severed down the middle and everything behind the knee indents removed to get it as narrow as I possibly could to fit the fuel cell and create the new tank cover.”
Now, finally, Rob could turn his attention to that subframe and tail, and you can see how a project in the hands of a first-timer can go off track if you try to perform tasks in the wrong order. But you can see from Rob’s work on the beautiful new lines of the frame, which now run to a higher point than the factory steel, that this is definitely not his first rodeo. His skills also shine through in the metalwork that forms the tail section, the lines brilliantly picking up those of the tank and helping to create a contemporary cafe racer vibe. Once he’d made the seat pan, it was shipped down to his brother who owns TUFFSIDE, and Chris stitched up the stunning carbon and leather look.
For the perfect hue, Rob found the colour in the Audi catalogue, Ducati’s owner and the Nardo Grey gives the S2R that true European exotic appearance. To keep that look going, a host of other parts were sent out for powder coat and Cerakote, with a mix of satin and matte black used for that first-class style. Having totally rebuilt the wiring loom and neatly routed it from one end of the bike to the other, a host of high-end parts complete the lighting. The front headlight is an LED unit from Motodemic. While a set of turn signals from Motogadget sorts out the front and the rear uses a Kellermann 3-in-1.
The S2R is known for its brilliant handling, but leaky front forks give you anything but, so Rob stripped them down and has rebuilt them with K-Tech springs and new seals. To bring the rear end up to scratch, the stunning single-sided swingarm is now controlled by an adjustable YSS shock. A set of new Dunlop tyres go on the lightweight factory Marchesini wheels and the brakes have been upgraded with Hel lines and a full set of DP pads. To give the rider improved control, the clip-ons are from Woodcraft who make some of the best bits in the biz, as do Rizoma who supplied the rearsets.
The brilliant Desmo donk doesn’t miss out either, as Rob stripped it all down and thoroughly cleaned the motor, while also finishing the covers in a matte Cerakote. A set of new belts was added, always a good idea on a Ducati, the valve clearances were checked and a set of new stainless bolts was used for the reassembly. The exhaust is a full custom system, with a redesign to the mid-pipe to get the angle of that Hindle muffler to match more elegantly to the frame’s new lines.
A reflash of the ECU elicits some more power, improves fuelling and allows for the stock gauges to be replaced by a Koso unit. The “look fast sitting still” goal of the build has more than been achieved with this beautiful bike and you can learn many of the tricks of the trade by heading over to the Origin8or YouTube channel.