Source: Bike Bound
The first custom creation to roll out of Donut Garage…
In 2002, Harley-Davidson released the V-Rod, the first of the VRSC (V-Twin Racing Street Custom) series — a line of muscle bikes whose 1131cc Revolution V-twin was the Motor Company’s first liquid-cooled engine. This V-twin was actually developed from the Harley VR1000 AMA Superbike engine with the help of Porsche Engineering.
The original version made 115-125 brake horsepower, enough to propel the +600-lb cruiser from 0-60 mph in 3.1 seconds and up to a top speed of 137-144 mph.
“The engine is the real reason for this bike’s existence and it’s an absolute classic. Forget all preconceptions you’ve got of this bike and let the engine do the talking…” –MCN
The V-Rod has long been a favorite of Mark Hawwa, founder and director of both The Distinguished Gentleman’s Ride and Throttle Roll. Mark rode a V-Rod nearly a decade ago and loved the bike. He harbored the idea of a custom project based on the beast, but his love of cafe racers kept the V-Rod dream at bay until he met a builder with the skills to transform the big muscle cruiser into something leaner, meaner, and wholly unseen in the annals of custom motorcycledom.
That builder was none other than our friend Noel Muller of Black Cycles Australia, one of the most talented, prolific, and versatile bike-builders not just in Australia, but worldwide. Mark had seen and fallen in love with Noel’s Ducati Turbo, and as he watched Noel unload no fewer than six of his custom creations for Throttle Roll 2023, Mark knew he’d found the right man for the job…though it would take a little convincing.
“In September 2023 I met Mark Hawwa when delivering bikes entering in Throttle Roll. He asked me if I’d ever be interested in building a V-Rod. I said it’s not really my thing, but then he said ‘a V-rod Cafe Racer’ and I said ‘Hell yeah!’” -Noel
They started with a low-mileage 2006 VRSCD Night Rod imported from Japan, working to merge the bold, powerful character of the V-Rod with the precision handling and sporting style of the café racers that inspired Mark to create the Distinguished Gentleman’s Ride in the first place:
“The concept was simple but daring — a fusion of Harley-Davidson’s iconic V-Rod with the aggressive lines of a café racer.” -Donut Garage
Known as the “V-Racer,” the bike would also set the tone for Donut Garage — a new space in Sydney, Australia launched by Mark and Simon Francis as a hub for motorcycle and automotive enthusiasts of all types, merging motoring culture with the aroma of fresh donuts…what could be better? Donut Garage already houses several iconic vehicles like a 1967 13B Mazda Cosmo, 20B Cosmo, series 3 RX7, and even a DeLorean, but the V-Racer would be the first custom creation to emerge from the space.
Months of hard work, innovation, and deep collaboration between Mark and Noel followed, as they worked to create a custom that blended the raw power and muscle of the V-Rod twin with the sleek, minimalist lines of a café racer.
The bike was stripped down and the first major challenge was the very large 38° rake angle. In order to reduce the rake for sportier, more aggressive handling, Ride Dynamics completely rebuilt a 2006 GSX-R front end for the V-Rod, lowering the inverted forks internally.
These forks were paired with custom triple trees from Michael of MDS Fab, who CAD-designed and machined them from 50mm 6061 aluminum to adjust the rake to a steeper 34°. The font end was then outfitted with billet clip-on bars, Reinard switches, Beringer brakes and levers, and Motogadget electronics to make for a much racier cockpit and riding position.
The undercarriage was rounded out with custom YSS rear shocks and a pair of custom 18-inch tubeless spoked wheels from Adrian Packett from Canyon Motorcycles / TT Wheels, complete with billet hubs and high-performance Beringer brakes. These were wrapped in Metzeler Marathon Ultra rubber for better road-holding and feel.
Justin from Popbang Classics designed and built the rear drive pulley, mimicking the intricate spoked design of the custom wheels, and he also spent hours prepping the bike for paint.
“As we all know, painting is 99% preparation, identifying every little pinhole and imperfection to eradicate before laying the paint down. If you look close enough you’ll find that many parts of the bike were crafted in chopped and twilled carbon fiber, along with the fairing windshield and top panels. A painstaking job that took a god-level amount of time and precision for Noel.”
Noel combined parts from a Honda CB and Ducati Monster to create the one-of-a-kind tank cover, and the aluminum top fairing took three rounds of fabrication (and destruction) until he was happy with the result.
The color is a subtle echo of the the production matte sand color, revised in a sleek gloss finish, and many of the other components were coated in satin black Cerakote by Competition Coatings.
The rear frame was raised 60mm for a longer, sleeker profile, and the tail section is a modified Harley Street 500 unit. The aluminum seat flips up for access to the newly designed fuel tank, which replaces the stock under-seat tank. Carman’s Auto Trimmers handled the black leather seat.
Of course, the V-Rod was Harley’s first liquid-cooled production bike, but as with many custom builds, the cooling system posed a challenge:
“The trademark V-Rod radiator/oil cooler covers were a challenge, so I’ve made up a more flowing aluminum full length covers including a full aluminum and stainless mesh front piece which fully encloses the cooling system and wiring and modified the oil cooler to narrow the lower section.” -Noel
Noel also fabricated the aluminum belt guard, front pulley guard, lower front frame fillers, overflow bottle, air box, horn cover, keyless start cover, and many more fillers and parts with the goal of building the bike to showroom standard, as if it were a never-released Harley-Davidson prototype cafe racer.
The clear window stator cover comes from DGD Custom, giving a peek into the belly of the beast.
One of the most striking elements of the build has to be the handmade 316 stainless steel exhaust. It’s welded from more than 45 separate pieces and incorporates a flex joint to accommodate the rubber-mounted engine — trick!
The V-Racer represents one of the most high-profile custom collaborations we’ve seen, merging the vision and passion of DGR creator Mark Hawwa with the fabrication and engineering excellence of Noel Muller and Black Cycles Australia. The result is a sleek, muscular machine that recalls a lioness bounding across the savanna in pursuit of prey…and with one hell of a V-twin roar.
Bravo to Mark and Noel for a job well done, and we can’t wait to see what rolls out of Donut Garage next.
Build Specs
Year and Make: 2006 Harley-Davidson
Model: VRSCD
Fabrication by: Black Cycles Australia
Assembly by: Black Cycles
Time: 400 hrs
Engine
- Capacity: 1130cc
- Type: Liquid-cooled 60-degree tandem V-twin
- Valve arrangement: DOHC; 2 intake, 2 exhaust valves
- Displacement, bore x stroke: 1130cc, 100 x 72mm
- Compression ratio: 11.3:1
- Carburetion: EFI
- Lubrication: Wet sump, 4.5 qt.
- Final drive: Belt
- Air cleaner: RAM AIR
- Pipes: Custom Black Cycles 316 stainless steel and full handmade box muffler
- Other Modifications: DGD Custom clear view stator cover
Transmission
- Transmission: Wet clutch, 5 speeds
- Year: 2006
- Shift: Custom
- Rear Sprocket/Pulley: Stock front & custom-made stainless steel spoked rear pulley
Suspension / Wheels
Front
- Type: 2007 GSX-R inverted forks rebuilt by Ride Dynamics
- Extension: Lowered 60mm
- Wheel size and type: 19″ TT smooth spoked
- Hub: Canyon TT Custom (California, USA)
- Brakes: Beringer billet radial 4-piston
- Lines: Hel Performance
Rear
- Type: Beringer V-Rod bracket
- Size and type: 18″ × 6″ TT wheels smooth s/s spoked
- Hub: Canyon TT Custom Non-Cush (California, USA)
- Brakes: Beringer
- Lines: Hel Performance
Accessories
- Bars: Billet clip-ons
- Headlight: Purpose Built Moto 5.75 billet with LED center
- Tail light: Kellerman all-in-one micro
- Seat: Custom by Black Cycles & covered by Carman’s Auto Trimmers
- Speedo: Motogadget Pro
- Blinkers: Kellerman micro
- Front pegs: Black Cycles custom aluminum
- Rear pegs: None
- Petrol tank: Black Cycles custom alloy 11-liter
- Oil tank: Stock
- Front guard: Aluminum, carbon fiber skinned
Finishes
- Painter: Popbang Classics – Gold Coast
- Colour: Chopped carbon fiber, mustard yellow, custom grey & matte black
- Mural/decals by: Popbang Classics
Other Outstanding Features
- Beringer hand controls, switches are from the Czech Republic
- All body panels are handmade from aluminum by Black Cycles & “tank” top cover is Honda center blended to Ducati outers.
- Rear shocks are YSS, Oberon oversized clutch master cylinder, custom billet top & bottom
- Triple trees by MDS Fab at Cooper’s Plains (Brisbane).
- Metzeler tires (200mm rear) & 120mm front.
- Beringer oversized full floating discs all around.
- Radiator & oil cooler are modified originals.
- Engine and other parts ceramic coating by Competition Coatings.
- Wiring by Popbang Classics.
Full Gallery
Builder Thanks
Black Cycles Australia, Popbang Classics, MDS Fab, Carman’s Auto Trimmers, Motogadget, Canyon TT wheels, Beringer Brakes, YSS suspension, Oberon, Hel performance, DGD Custom, Metzeler, Motul, Competition Coatings, Ride Dynamics
Follow the Builders
Donut Garage: www.donutgarage.co | Facebook | @donutgarageofficial
Black Cycles Australia: Facebook | @blackcyclesaustralia
Mark Hawwa: @markhawwa
Photography: Pat Stevenson | @patstevenson
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