After watching a computer controlled 5 axis milling machine turn a solid block of aluminum into a very precise facsimile of a motorcycle helmet, you might get the impression that the days of low tech hands on work are over. After all, who can compete with all of that industrial high tech capability? Well, take a look at this. Over in India, the Bajaj Pulsar is the largest selling motorcycle. It’s very functional and does the job it’s supposed to do but, every one looks like every other one, hundreds of thousands, perhaps millions, of the same bike. Sounds like an opportunity for a little creativity to make them look unique.
Akshay Sharma teaches in the industrial design department at Virginia Tech but he grew up in India. He learned about scooters and motorcycles at a very young age and developed a fascination for them that carries through to the present day. Over the years, he thought he would like to build something special and finally decided to do something about it.
Every year Akshay travels home for the summer and he designed a custom body kit for the popular Pulsar, but he didn’t want to build a one off, he was thinking of making a custom kit for motorcycle enthusiasts in India so they could personalize their own bike.
Taking his design to India, he assembled a small team, of dedicated hands on workers who created the clay mockup, made the molds for the fiberglass and put together the body. This very low tech operation resulted in a motorcycle that looks quite distinctive and attractive.
You can tell from the photos, this was not created in a multi-thousand square foot high tech factory, it was done in the most basic working conditions by a team of hands on builders.
Costs for the whole project were very low:
Used Bajaj Pulsar – 400.00 USD
Getting the clay model done, and the molds made – 150.00 USD
Wheels, new tires- 150.00 USD
Paint – 75.00 USD
Miscellaneous – 100.00 USD
Akshay sums it up as, “Roughly $900.00 and an unlimited number of thumbs up, whenever I ride it.”
It looks like and sounds like the kind of project anyone could do if you set your mind to it.
As Akshay says:
It has also been a test for my own conviction. We all talk about doing this and that. I was like that as well, but this one time, I just decided to go with it, and the result has been nothing short of amazing. I surprised myself. It still needs lot of fine tuning, but that I think is a positive. People who don’t take risks, make very few mistakes, and I was getting to be like that.
I think it’s a very nice example of hands on work by a group of “doers” who just made it happen. The process could be repeated by many others on projects of their own, no huge investment necessary. I like it. Nice work, Akshay!
Tin Man 2 says
Nice looking little bike, before and after the Body Mods. I wonder about the bikes specs, c.c.s and capabilitys. I like small bikes,and this is just a neat little standard.
Swagger says
Looks neat! I have a ‘thing’ for the do-it-yourselfers out there who do just that.
It’s one thing to talk about all our neat ideas that we’re all sure would go like wildfire….a totally different thing to actually take action. Nicely done fellas….
AlwaysOnTwo says
Not only is it “down and dirty” as in cool and easy on the wallet, it goes to show what can be appealing to an enthusiasts without mega inches and/or 18K on the tach.
There are quite a few non-Chinese small displacement bikes in Europe and India that never make it to the USA, and I think it is a sad affair to loose out on those choices for the wimpy twist and go GY6 clones. Maybe if not so many Americans weighed more than the bikes the marketing would be easier.(?) It can’t be the EPA requirements alone.
And look at those price parts. I’d have a chore to find a gallon of decent non-fleet epoxy paint for that price, and wheels and tires for $150?? Can’t be done States side
even for a GY6 clone scoot at that price. So I’m thinking that in relative terms these guys spent a lot of cash in comparison to some kid living in Malibu that spends a few grand on bling for his ‘Busa.
But back to the subject bike…that’s a lot of detailed work that is all on cue for the vehicle. Well done.
Very well done.
JerseyMayhem says
Good looking bike, more after than before. Wish the pics were of the same side, but i really like it, I dig stuff people do themselves without any computer aid. Computers make it easier to “see” your product but you cannot beat jumping in and going for it. Good job!
knotlinks says
Great job, looks like a brand new bike. Nice color choices, too. Makes you want to take up fiberglassing.
PaulN says
I think my Virago is in trouble!. I’ve been thinking of reworking the subframe for a long time now. I never even considered clay modeling, but it seems like a great idea. The car designers used to do it all the time. Now, where did the kids hide their Play-Doh?
todd says
Great project. Knowing India, he can probably get all that stuff made for less than $50. A friend of mine brought back a few spare Jawa carbs and parts for me. He said a brand new Jawa carb was $25.
I bet he does extremely well with this. It’s such a huge market. BTW, if you look up the Pulsar, there are many different styles, the new ones look more sporty. Some are 220cc, approx. 20HP, in other words, enough for 80+MPH, more powerful than a Honda Nighthawk.
-todd
Phoebe says
Ashkay’s work is very nice! Looks like he made a great little streetfighter.
Not to downplay Ashkay’s impressive accomplishment, but this type of stuff is fairly common in the streetfighter scene. A lot of people make their own fiberglass bodywork from foam or clay plugs, some even will go to metal.
WRXr says
Way to go! I also think their headlight mod is quite interesting.
WRXr says
BTW: I like how there seem to be many more posts about bikes from countries other than the US, especially emerging markets, India in particular. Keep it up.
Erick says
the original bike is the pulsar 150 on this picture, they all have a unique combustion system with twin spark in one cylinder. have a great value for money even at my country (no i’m not from india), the plastic and finishing is cheap, but the engine is reliable enough to do everyday chores. still thinking of buying a brand new pulsar 200 for around $2000 (including import taxes bla bla)
Chris says
India has a really cool selection of small displacement motorcycles. Honda has many India-specific bikes too! http://www.honda2wheelersindia.com/
Some of these are really awesome.
Marvin says
That is nice work, I work a lot in India and can attest to the size of the market. I hope he has some good manufacturers and distribution networks set up. I have always worked in niche engineering and while its nice to be on first name terms with your customers I bet it would be a great feeling to suddenly and unexpectedly spot one of your creations in a town or city you were visiting for the first time. I have also had a go on one of those pulsars and …. brace for British blasphemy…. if I was living in India I would chose a pulsar over an Enfeild every time they are so much lighter and better suited to in, out and weave style of urban driving.
Sportster Mike says
Great looking modern looking bike but it means a 1up no passenger and no panniers bike? for India where bikes are used for everything??
Having been to Goa and seen 5 up on their bikes, sorry 6 up, Mum, Dad, the 3 kids and a pig (still alive) – cue this little piggy went to market..
But still a nice little bike..
youngkrankenstein says
Bikes Like are popular in argentina, But incredibly expensive… 4-6 USD for a little 250 single cylinder type deal. Saw one the other day with stickers that read “turbo” on teh gas tank. The owners rarely take good care of them! If I had one I would be like its father and treat it as gold. A used honda from the 70’s will go for 5 grand! Anyone want to ship me a cb750 from some barn in Minnesota?
Akshay Sharma says
Thanks a lot for all the positive comments.
It has been a great journey so far, and this time when I go to India for summer again, I plan to take the operation to the next level. We will start offering the kits.
I just want to make sure that I give credit where its due.
Besides me, the other significant contributors to the project have been:
Rohit Shrma – My younger brother
Naveen Panchal, Ajai and aArun – all the fibre glass work.
Thanks again for all the comments.
Akshay
AlwaysOnTwo says
@Akshay
The thanks go to you and those as named. Not only is the bike a great example of craftsmanship, it is a credit to the differences of ethnic and cultural backgrounds that merge on two wheels.
Not many truly acknowledge the passion of riders that aspire to the peer review of smaller displacement machines. Or why such attention to detail would be spent on a ride that costs less than the right hand crankcase of any Brit or US sport or cruiser.
Yours is a pinnacle example of the true obsession.
Utkarsha says
Thank God I stumbled:
Here in India 70% transport depends on bikes and 1 of every 10 bikes is pulsar. Its such a nightmares to pull up at the trafic light beside another two bikes of same kind and probably same color (They come only in five color options). So congrats Akshay, and if you do the kit project on a mass scale, you will be a great help to pular cult and pulsar maniacs. ALL THE BEST
Akshay Sharma says
I am working on getting a website up and running for this, and soon you will be able to get lot more information on how to get this kit and install it yourself, or send us a donor tank get it all finished and painted.
Thanks a lot for all the support.
Akshay
Alexander says
What a cool design to personalize your bike! Two thumbs up on actually DOING it! And doing a good job of it to boot!
Here in South Africa we have been able to buy the Bajaj bikes for at least two years. They are becoming more and more popular, as although they are slightly more expensive than the regular Chinese fodder, they have surprisingly good build quality. Unless I’m mistaken, Bajaj is actually the worlds 3rd largest motorcycle manufacturer in terms of number of bikes made/sold. The bikes range from 100cc to 200cc, and can easily give over 60 kilometers to the liter! (141MPG (US)) This is normal use, as under good circumstances the 100cc version gives up to 70km to the liter (197MPG (US)). They look good, sound ok, and go and go and go and go.
I’m sure that there is an untapped market in the ‘states amongst students, and the environmentally conscious, or just people wanting a fantastic bike that looks good, is easy to live with, commutes like a breeze, and which will last without giving any hassles. Somebody could make some money here…..
Fernando Pernas says
It is very satisfying when you have an idea about transforming something good to make it better or just different, and you actually do it . Then you sit back and look at the results … it’s a great feeling of personal satisfaction.
My advice: continue forward until you reach your goal!!!
vicky says
i have also modifes my pulsar 200. but i have facing problems related to engine like my bikes clutch plate got damage early. The average had gone to its worst state.At the end i have understood that after modifying the bike the bbike looks nice but ultimately its performances got decreaced
Vijay says
Hi Akshay… I always have been intrested on changing my bike design however didnt have proper resources.
– I would like to discuss and get my bike done. I can send my bike’s pics which i did manage to build.But not quite well due to lack of resources and no one who can make moulds.
My number is 9900831831. I am currently in Bangalore and originally from Mumbai. So let me know if you are intrested in building my bike…
I am also getting the engine Overhalued by Ten10 Racing and post which i think i need a god design.
Regards
Vijay Hansora
Charles Han says
Akshay hates Star Wars.
HPNOTIQ says
Great work there! Keep it up, and hope I’ll be seeing your Custom Kits on sale out here. Oh! And I own a Pulsar myself. It comes presently in 4 variants. Down from 135cc LS(Light Sports) up to 220cc, along with 150cc and 180cc in its range. Fit & finish is not upto the mark, but like someone said here, it does its job, and it does it well. I’ve got the 220cc 21bhp version(comes with Projector headlamps/brightest and most well lit in India now). Acceleration is quite good and strong.
Would be great if you could come up with Mod Kits for the 220cc version as well. Its got a half-fairing, up front.. Looking forward for this… Very nice job. Keep up the good work..