Take one of the world’s most popular middleweight nakeds, strip it back to its bones, and then rebuild it with enough CNC wizardry and 3D-printed trickery to make even Honda blush. That’s exactly what the brothers, Filippo and Giacomo Tagliabue, at Italy’s FTG Moto have done with this classic Honda Hornet 600. The goal was never to disguise the iconic aspects of the Hornet, but rather to enhance every aspect of the bike with high-end techniques. Dubbed ‘Athena’, it’s a sharp-tailed, HRC-liveried streetfighter that proves even a mass-produced commuter can rise again as a one-off goddess. And like the mythical namesake, this Hornet isn’t here to whisper; it’s here to make itself heard.
Based in the industrial and economic powerhouse that is the city of Milan, FTG Moto have always been innovators in the custom motorcycle scene. Their creations are like no other; they don’t play by the rules, and the brothers Tagliabue were early adopters of new technologies to help give them an upper hand. But they don’t rely exclusively on CNC machines, CAD software and 3D printing, they’re just as adept with a grinder or basic hand tool, and the idea behind this build of the iconic Honda Hornet was to combine all of their skills.
“Our aim was to show how even a mass-produced motorcycle can be reinterpreted into something unique, preserving its DNA, while giving it a brand-new soul.” And while stripping down the hugely popular middleweight naked, the guys knew that retaining the stock tank and keeping the engine covers exposed would ensure that there was no doubt in the mind of any onlooker that this was once a Honda Hornet. Then, the rest of the bike could serve as a demonstration of their skills to create truly groundbreaking parts and pieces, and it all starts with that stunning subframe, modelled in CAD.
The advantage of using the latest in design software and manufacturing techniques, is the ability to virtually test the component using finite element analysis, which predicts how a product or structure will behave under real-world conditions like forces, heat, and vibration. Then any necessary alterations can be made, so by the time they load a big chunk of aluminium into their CNC machine, they know the end product will be exactly as they planned, in both looks and performance. The incredibly lightweight piece is insanely strong, and the exacting process means it bolts up perfectly, and houses all the required mounts for the parts to come.
Those include the trick number plate hanger, 3D printed from a PA material, which incorporates precise holes that allow the fitting of LED lighting into the product. Not only does this bike benefit, but it also allows the guys to use the Honda to highlight the kind of products they can make for any customer. Next to go onto that trick subframe is the tail cowl, and once again, it’s all high-tech goodness that comes to the party to bring the part to life. Having designed the piece in the style they were after, it is then 3D printed. The material? Carbon-Fibre Reinforced Polypropylene, a high-performance composite material that combines the strength and rigidity of carbon fibre with the versatility of a poly product.
The same technique is used to create the front cowl and fender combination, with the mask-like design accepting twin homologated LED headlights, the upper area serving as the perfect recess for the Daytona digital dash, and the high-mount front fender giving the urban assault vehicle vibe. But to craft the seat, the guys reverted to the old school approach, forming up a fibreglass base that flows perfectly up to the tank. Then getting very Milanese, with a three coloured leather combo for the saddle itself, all beautifully stitched together. To lay the colour across the rest of the bike, the guys picked out the HRC hues and had Kustom Family lay down the paint in a modern design.
The wheels are colour-matched to suit, and have been wrapped up in some street-oriented enduro tyres from Pirelli. And even the USD Showa forks get a little custom touch, with brake line hangers keeping things neat and tidy. But it’s the humble Honda’s controls that have been totally ditched, and FTG have gone to town creating some truly special parts. The CNC-machined switch blocks, with anodised buttons, double up as the mounting blocks for the Accossato master cylinder and lever combination, with even the bleed nipples incorporated into the solid design. The lever guards are another incredible piece, a combination of machined aluminium and 3D printed Nylon, they house LED indicators in the tips. To control the rear brake and shifting duties, the guys wanted to use more Accossato goodies.
But with no rearset mounts available for the Honda Hornet, they simply designed their own and machined them from matching billet aluminium, anodised in Accossato black. The legendary Honda 600cc four-cylinder engine is another beneficiary of this high-tech manufacturing, allowing the brothers to go with pod filters for that sweet intake sound, while retaining all of the benefits of an airbox, with a custom 3D Carbon PP item that still houses an IAT sensor. To finish the build, the welder was fired up for a full stainless steel exhaust with HP Corse muffler. And the end result shows what can be achieved when you combine ultra-modern and traditional techniques in one very well thought-out package; the future of custom bike building is here.
[ FTG Moto ]