The third of four chapters, detailing a motorcycle build project that Diamond Atelier will be sharing with us over the next few weeks.

For their latest project, the guys at Munich-based Diamond Atelier have undertaken the challenge of flipping a brawny off-road Suzuki DR650 into a more stylish, urban-friendly cafe racer. If you’ve not read it yet, make sure you check out part one and part two of the project.

Part three continues below, courtesy of Tom Konecny and Pablo Steigleder from Diamond Atelier, shot by Philipp Wulk.

"In today’s episode we will focus on all remaining fabrication work – especially all sheet metal body parts."

"We start off with a piece of hard PU foam, which is glued in place and filed down until we reach the desired shape. This form might seem rather simple, but it is crucial to get the proportions right at this stage, since it is a lot easier to make corrections on the foam than on metal."

"The seat cowl is made from five pieces in total. We start with the top piece since it is the most complex one, especially with the light bends on both sides. After that we proceed with the two sidepieces, which have to be perfectly symmetrical because any flaw will be visible afterwards. The bottom piece and the one facing the seat are the easiest to build and therefore the last step."

"We weld the sheet metal together and smooth out all welds using our Festool eccentric sander to tell if the rough shape needs any more work."

"Minor imperfections like a scratch can be taken care of with filler, but you can’t overlook an uneven surface. Our seat cowl seems rather good though, so we proceed with the final steps."

"Lastly we spray on a super thin layer of filler and sand it down with up to 2000-grain paper for a glass-like surface. Everything seems to be just the way we planned, so we can prepare our seat cowl for paint."

"Almost the identical procedure is followed with the front mask. But since the shape was more complex on this piece, we had to use a bit of zinc to make sure we fill the gaps between the spot welds."

"Zinc is a little difficult to handle sometimes, but the results are quite decent for minor corrections on sheet metal. The finished mask will be revealed in next week’s episode."

"We finished almost all of the bodywork on the DR650 today and are ready for paint and the final assembly. Stay tuned for the last part of our tetralogy."

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