When most people talk about starting from scratch, they’re usually exaggerating. Rusten Smith had no such luxury. His 1995 Yamaha Virago 535 arrived completely disassembled and packed into boxes, looking more like the aftermath of a garage clean-out than the beginning of a custom motorcycle. But where others might have seen a headache, Rusten saw opportunity. Having always wanted to build a cafe racer of his own, he decided the forgotten V-twin would become the perfect canvas for a first full-scale custom project. One year later, the result is ‘Classy Nuisance’, a beautiful hand-built machine that sheds 30kg from the stock bike and bears little resemblance to the Yamaha that donated its VIN plate.
Viragos have long enjoyed a second life in the custom world. Yamaha’s air-cooled V-twin platform is reliable, affordable and mechanically straightforward, making it a favourite among garage builders looking to create something unique without breaking the bank. Most projects focus on simplifying the factory package, but Rusten’s ambitions went much further. Rather than modify the existing chassis, which is awful, he placed the original frame in a jig, retained the steering neck to preserve the bike’s identity and began designing an entirely new structure around it.
Before a single tube was cut, the new chassis was mocked up using PVC pipe. The inexpensive stand-in allowed Rusten to experiment with proportions and geometry until the silhouette matched the vision he had in mind. Once satisfied, he recreated the design in chromoly steel, producing a one-off frame that transformed the Virago’s stance. The swingarm received similar attention, modified to accommodate a modern 2017 Yamaha R1 rear shock. Up front, however, Rusten resisted the temptation to install upside-down forks. Instead, he rebuilt the originals with stiffer springs, preserving the classic appearance he wanted while significantly improving the bike’s handling.
The fuel tank became another major turning point in the build. Rusten selected a 1974 Suzuki GT550 tank, then modified it to suit the proportions of the new chassis. With the tank locked into place, attention turned to the tail section. Rather than purchase an aftermarket seat unit, he measured the tank, adjusted the dimensions to maintain visual balance and created a mould from floral foam. Layers of fibreglass followed, producing a completely bespoke rear cowl whose shape mirrors the lines of the tank while helping define the bike’s sleek cafe racer profile.
Beneath the bodywork, the Yamaha V-twin received the same meticulous treatment. The engine was stripped, inspected, refinished and reassembled before being slotted back into the new chassis. Rusten also designed and fabricated a single-carb conversion manifold from aluminium, simplifying the intake system while cleaning up the engine’s appearance. The exhaust system was equally ambitious. Built entirely from stainless steel tubing, the headers and mufflers were painstakingly finished through a multi-stage sanding and polishing process until they achieved a mirror-like shine that contrasts beautifully against the dark green bodywork.
One of the most impressive aspects of the build is what you can’t immediately see. Determined to keep the motorcycle visually uncluttered, Rusten built an entirely new wiring harness around a Motogadget M-Unit Blue control system. Every wire was carefully routed out of sight, while additional components, including the Motogadget Mo-Lock, Rick’s Motorsport Electrics charging components and a Daytona Velona gauge, helped modernise the bike without disrupting its vintage-inspired aesthetic. Purpose Built Moto push-button controls, lighting and indicators further contributed to the minimalist presentation while offering modern reliability.
The Australian company’s influence extends beyond the parts catalogue. Rusten credits Purpose Built Moto founder Tom Gilroy as one of the key inspirations behind the project. After years of following the Brisbane-based workshop’s builds, a handful of encouraging conversations with Tom provided the extra motivation needed to push the project across the finish line. It’s a reminder of how much the custom motorcycle community continues to thrive on shared knowledge, encouragement and a willingness to help fellow builders tackle ambitious projects.
Finished in Lotus Dark Verdant Green with custom-mixed gold accents, Classy Nuisance strikes a balance between elegance and attitude. The name itself came from two very different reactions during the build. While one neighbour lodged a nuisance complaint during the engine tuning process, a friend described the completed motorcycle as classy. Combining the two proved too good an opportunity to ignore. Built entirely in Rusten’s home garage over the course of a year, with virtually every component either fabricated from scratch or heavily modified, Classy Nuisance is exactly what a great custom motorcycle should be: personal, technically ambitious and impossible to mistake for anything else.
[ Photography by Michelle Weesies ]