Welcome back to our Project Delta series, where we’re taking a Royal Enfield Super Meteor 650 and reimagining it from the ground up. In our last episode, you saw the initial teardown and learned about our overarching plan—stripping the bike to its bare essentials, sketching out a girder front end, and setting the stage for the radical changes to come. Now, we’re rolling up our sleeves to finalize the front suspension, finish off major frame modifications, lace up some new wheels, and get the bike to a “test rolling” milestone. This phase is where the project starts to feel real.
One of the biggest talking points of this build is the custom girder fork. We took a classic design concept—steeped in heritage from earlier Royal Enfields like the Flying Flea—and gave it a Purpose Built Moto twist. In Episode 1, we had worked out the girder’s geometry and built the core structure. In this stage, it was time to make it rideable and refine every detail.
Fitting the front shock setup was high on the priority list. We opted for a modern air shock that allows more adjustability than a traditional coil or leaf spring. This choice keeps the vintage look intact but gives us the ability to dial in the damping for a smoother, more controlled ride. When it all came together, we could finally stand back and see that unmistakable girder silhouette—raw, mechanical, and built for the long haul.
“We wanted to create a really classically styled front end, something that didn’t mimic the Royal Enfield girder forks of old, but you could tell where they came from,” Tom explains. “You could see the inspiration, but I wanted to obviously add my own touch to it.”
With the geometry set, we made sure the steering remained free and precise. Proper alignment is everything with a girder front end—it doesn’t take much to throw off handling. To ensure we got it just right, we laser-checked everything from rake and trail to how the fork would compress under load. After a final pass of weld cleanup and some well-placed gussets, we were satisfied this girder front end was as functional as it was eye-catching.
In parallel with the front end, we moved on to complete the frame modifications we’d started in Episode 1. At this point, the big cuts were done—like removing the stock subframe and prepping for a monoshock. Now came the fine-tuning:
- Monoshock Mounting: We designed a new mount near the engine’s pivot point to anchor the custom Nitron shock. Welding in the brackets and checking for clearance was critical. We needed to make sure the monoshock wouldn’t foul on any wiring, chain run, or our soon-to-be-installed bodywork.
- Neck and Backbone: We’d slimmed down the main backbone to allow a narrower, hand-built fuel tank. Around the neck, we fabricated lightweight gussets to replace the bulky cast sections. The result was a cleaner, more classic look that also shaved off some weight.
- Oil in Frame Touches: One of our wilder ideas was redirecting the oil to flow through the frame rails, reminiscent of older motorcycles with simpler systems. We added a few finishing details here—machined junctions and stainless steel lines where needed—making sure everything fit seamlessly alongside the factory engine mounts.
By the time we were done, the Super Meteor’s tubular frame hardly resembled the stock layout. Slimmer, lighter, and fully geared for that vintage-meets-modern vibe we’re chasing.
To amplify that “board track” style stance, we decided on a 23-inch front wheel and a 19-inch rear, both built from scratch. With a girder fork, proportions matter a lot—too small of a front wheel, and you lose that authentic old-school presence. Too large of a rear wheel, and the bike can look unbalanced. After a few sketches and geometry checks, we settled on this 23/19 combo as the sweet spot.
We sourced hubs that would handle a single disc up front, then worked with local specialists to lace them to custom clincher rims. Getting the correct spoke angles and tension is an art form in itself. Any slight miscalculation can lead to wobble at speed or, worse, a failure down the road. Once they were built, we mounted vintage-pattern tyres to complete the retro aesthetic.
“We had specialty wheels handmade locally here. They’re one of one,” Tom says. “It gives the bike that vintage board track look we were after. The geometry changes drastically with that big front wheel, but it ties right into our design DNA.”
With new wheels and the girder up front, we could finally place the bike on the ground, roll it around, and see how everything lined up. This is the point where the project starts feeling less like a concept and more like a real machine.
Moving rearward, we turned our attention to the newly installed monoshock. We’d chosen a single Nitron shock for its excellent adjustability and the distinct look it brings compared to a traditional twin-shock setup. Attaching the swingarm and testing the suspension travel were the next steps. We wanted enough movement to handle real-world road conditions, but also a firm, responsive feel when you twist the throttle.
The seat design was up next. We leaned into a bobber-style floating seat pan, anchored just over the monoshock mount. This approach gives the rider a more direct connection to what’s happening beneath them—every engine pulse, every bump in the road. It’s a nod to old-school motorcycles that were a bit rough around the edges, but pure in riding feel.
We fabricated a simple bracket to hold the seat, making sure it flowed visually with the rest of the frame. The aim was “form meets function”—it needed to look minimalistic and purposeful, but also stable enough for everyday use.
With the backbone modified, it was time to tackle one of the biggest pieces of visual real estate on any bike: the fuel tank. Cody, our in-house fabricator, took the lead on shaping it from raw aluminium. He’s been refining his craft for a while, but this was his first major tank project at Purpose Built Moto.
“Shaping a tank from scratch is always a challenge,” Tom points out. “It requires a keen eye, patience, and a willingness to start over if it’s not perfect.”
The design echoes the original 1950s Super Meteor and older Royal Enfields, but scaled down and narrowed to show off that parallel twin engine. Cody spent days forming the panels, tack-welding, and smoothing out each seam until it was fluid in shape. Then came the tricky part: fitting the modern fuel pump inside a smaller-than-stock tank. That puzzle required careful placement and some creative bracketry. In the end, we made it work without sacrificing the minimal silhouette we wanted.
At this stage, we had a partially assembled rolling chassis—frame, wheels, front girder, swingarm, monoshock, seat pan, and tank. Essentially 90% of the puzzle was in place, at least in rough form. Test-fitting all these parts together was a critical moment in the build. If anything was misaligned or clashing, we’d have to backtrack and make changes.
Luckily, it all started to come together more smoothly than expected. With the engine back in the frame, the new front wheel in place, and the seat giving us the right riding stance, we finally had something that looked like a cohesive custom bike. From the front, that tall girder fork and 23-inch wheel dominated. From the side, the monoshock kept the silhouette clean, while the trimmed-down frame and smaller tank gave the engine top billing.
“We’re about 90% done now,” Tom remarks with a grin, standing next to the bike. “That last 10%—the details, the finishing—usually takes the longest. But seeing it all come together, rolling around the shop for the first time, that’s the reward after so many long hours.”
With a rolling chassis in hand, we could shift our focus to the final details: exhaust fabrication, wiring, paint, and a myriad of small finishing tasks. The next steps would involve a full teardown for paint prep and final welding passes, reassembly, and then hooking up our electronics, including the PBM Black Box. We still had some work to do on the hand-shift arrangement and final seat upholstery, but the heavy lifting was behind us.
This test-rolling phase is always a highlight in our shop—it marks the moment when your design assumptions meet reality. A stroll around the block, even at low speed, can reveal any big “gotchas.” Thankfully, things lined up the way we’d hoped. That “vintage Royal Enfield” spirit was already evident in the bike’s profile, and it felt taut and responsive thanks to all the weight reduction.
In this second episode of our Project Delta build, you’ve seen us finalize the girder fork, complete major frame work, build and install custom wheels, and shape a one-off tank. We’ve pushed the Super Meteor 650 from a stripped-down frame to a near-complete rolling machine, brimming with vintage style and modern functionality. The sense of anticipation is off the charts around here.
Up next, we’ll wrap up any remaining fabrication details and prepare this machine for its transformation in the paint booth. Then comes wiring, the finishing touches on the hand-shifter and seat, and—finally—that all-important test ride. Stay tuned as we edge closer to unveiling the finished product.
For now, keep your eyes on our blog and YouTube channel, where we’ll share real-time progress and behind-the-scenes moments. As always, we’re grateful for your support and interest in the journey. Until next time—ride safe, keep experimenting, and never stop looking for what’s possible on two wheels.
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