Rebuild

Gas Bike

  • The challenge was to rebuild an existing motorcycle into a custom scrambler.

  • The build uses a 1991 Yamaha DT200 as the base, with added steel framing, a custom gas tank, leather seat, LED lighting, upgraded tires, suspension components, and a new fork kit.

  • The design aims to create a sleek, aggressive scrambler that performs off-road while remaining visually striking on the street.

This project involved a full transformation of a 1991 Yamaha DT200 into a custom scrambler-style motorcycle with a surfboard rack integrated into the design. The original frame was cut and rebuilt using steel to alter the bike’s proportions and stance, reinforcing its rugged character. A rear LED brake and turn signal strip was integrated directly into the frame to maintain a clean silhouette, while the gas tank and leather seat were fully custom mounted. Nearly every component was reworked or replaced excluding the engine and rear swing arms resulting in a bike that feels purpose-built and versatile, equally suited for off-road riding and urban display.
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Because this bike was going to be ridden on the road at high speeds, every decision felt high stakes. Cutting into the frame and rebuilding it meant there was no room for shortcuts, since it needed to be structurally sound and pass a safety inspection at a mechanic’s garage to be legal. Going through that process was nerve racking, especially as it was my first time working under real world safety constraints, but it forced me to slow down, think carefully, and design with responsibility rather than just experimentation.

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