When your day job is building headline-grabbing customs at Thornton Hundred, you’d be forgiven for wanting a break. But Jody Millhouse isn’t wired that way. Instead, he doubles down. This Honda XL600R was never destined for a client or a showroom floor; it’s a personal side project, built after hours, driven by a soft spot for one of Honda’s toughest old thumpers. Picked up over Christmas in what could generously be described as “running condition”, the old XL was a long way from the bike Jody remembered.
Originally red, it had clearly lived a hard life, with a mishmash of incorrect parts bolted on and plenty missing altogether. But beneath the grime and questionable fixes was a machine that meant something. Early in his career, Jody had built one and ridden it across Italy with his dad, so this wasn’t just another project; it was unfinished business. As with so many so-called runners, the truth revealed itself once the spanners came out. Dodgy welds on the subframe and an ill-fitting rear fender hinted at a past incident, likely a throttle-happy moment that ended in a looped-out wheelie. And as the teardown continued, more issues surfaced. Tired electrics, worn components, and years of neglect all demanded attention. Still, credit where it’s due, Honda’s big single refused to die. Even after decades of abuse, the XL’s core remained solid.
From the outset, Jody had a clear vision. A rendering mapped out exactly where this build was headed. The frame was stripped back, reengineered where needed, and refinished in white after essential brackets were re-welded for strength and safety. Even the footpeg mounts, snapped clean off, were TIG’d back into place, stronger than factory. The wiring loom didn’t stand a chance. Forty-year-old electric and reliability don’t belong in the same sentence, so the entire system was stripped and rebuilt from scratch. It’s a theme that runs throughout the build, if it couldn’t be trusted, it was either replaced, restored, or reimagined.
The rolling stock followed suit. The wheels were completely rebuilt, retaining only the original hubs. Fresh stainless spokes lace them to Excel rims, now wrapped in Dunlop rubber, giving the XL a far more purposeful stance. Suspension upgrades come in the form of a YSS rear shock, its red spring adding a subtle visual punch, while the front forks were rebuilt and paired with classic gaiters for that unmistakable dual-sport look. Then there’s the kind of craftsmanship that separates a builder from an engineer.
The original exhaust was beyond saving, rotted through by time and corrosion. With replacements unobtainable, Jody fabricated a new solution, cutting and shaping fresh metal before going a step further and 3D printing a die to form a new end cap. When a taillight surround proved equally elusive, the same approach was taken, sourcing plans online and printing the part in-house. Old-school skills meet modern tech, seamlessly. Up top, the XL gets a subtle but effective modern twist. A new front cowl houses an LED headlight, tightening up the front end without losing the bike’s utilitarian DNA. The seat tells a similar story, what started as a less-than-perfect eBay purchase was handed over to Dave the Trimmer, who reshaped the original foam and reworked the cover into a factory-fresh finish.
Mechanically, the attention to detail is relentless. The carburettor was rebuilt and correctly set up, the engine refreshed and slotted back into the frame with the kind of ease that only comes from knowing these bikes inside out. No manuals, no second guesses, just experience. Even the smallest details weren’t overlooked, with custom fasteners turned on the lathe and every bolt installed with a uniform orientation for a clean, symmetrical finish.
The braking system was treated to the same level of care, with the caliper fully rebuilt and fitted with titanium pistons machined by Jody himself. It’s overkill in the best possible way, because when it’s your own bike, why not? Visually, the transformation is striking. The white frame sets the stage for a red, white, and blue tank that absolutely pops, complete with in-house printed decals and subtle Thornton Hundred graphics as a nod to Jody’s day job. The swingarm, refinished in silver, ties it all together, completing a build that feels both period-correct and quietly modern.
And then, the moment of truth. First kick, boom. The big single fires into life like it’s got something to prove. A quick once-over to check every nut and bolt, and it’s time to ride. From tired old beater to a sharp, svelte restomod, the transformation is complete. Decades may have passed, but bikes like the XL600R remind us why big-bore singles still hold such a special place. Simple, tough, and endlessly characterful, especially when they’re rebuilt by someone who genuinely loves the ride as much as the wrenching.
[ Jody Millhouse ]