Jay Patel of J&D Customized Co. Is intimately familiar with the nuances of navigating roads on a reliable and iconic Royal Enfield. When we last discussed the matter, he had just introduced an add-on kit for transforming a Royal Enfield cafe racer into a customized version of the iconic Bullet motorcycle. Currently, we’re examining his latest creation, which just so happens to be built upon his beloved Royal Enfield Continental GT 535 platform.
This marks Jay’s third time customizing the GT 535; this time, he has decided to approach it with a slightly different methodology. By embracing a modern design approach, he decided to combine his skills with a hammer and shot bag for a final quality assessment.
Prior to the release of the Royal Enfield 650 series, the Continental GT 535 stood out as the flagship model in the brand’s lineup with its impressive capabilities. This milestone project marks the most significant accomplishment in Jay’s career as an engineer in India. When the time arrived for him to build his third Continental GT, he had a very specific vision in mind. To achieve this, he decided to blend the bike’s retro essence with a distinctly modern flair.
Jay initiated the project by tackling the GT’s exterior. The streamlined design of the vehicle’s body reduces its width at the rear, while a single component, responsible for supporting the engine, is employed throughout. Before building the other half, I created a wireframe of the tank and rear cowl to determine the overall posture of the motorcycle. Ensuring this stance was correct also required adjusting the Enfield’s suspension configuration. To mitigate staging issues, Jay reduced the peak at the manufacturing facility’s entrance by 2 inches. With the bike securely situated, Jay meticulously welded together a revised subframe.
Jay’s latest body of work is a bold exploration of angular, confrontational forms. The objective was to design a cutting-edge motorcycle that subtly alluded to the Continental GT’s racing roots while exuding a futuristic essence. With a fresh tank and tail, he designed a modern twist on the aftermarket fairings provided by Royal Enfield for the iconic 250cc Continental GT in the 1960s? “I’ve always been self-sufficient, taking on tasks independently,” Jay notes, “but this project marked my first experience working with large aluminum components.” Although I’ve fabricated aluminum tanks previously, designing the complete bodywork of a motorcycle presented an authentic learning experience.
The Continental GT’s sleek bodywork is crafted from a single piece of 1.5mm thick aluminum alloy, precision-formed to perfection. His angular gasoline tank, measuring longer than the standard manufacturing facility unit, stores approximately 14 litres of gasoline. He was pleased with the oil stage gauge on his air compressor and subsequently installed gasoline-stage windows on either side of the tank. The innovative fairing features a three-piece configuration comprising an entrance module and two symmetrical sides. The three components had been fusion-welded together for added stability and securely fastened to the bicycle using bespoke mounting hardware. Jay’s incorporation of aircraft-inspired louvres and rivets lends a touch of nostalgic charm to the fairing’s design, evoking a bygone era of adventure and exploration. To ensure the handlebars remain litter-free, the fairings’ sprint homes consistently switch between different swap blocks. Protected from the elements within a transparent perspex enclosure, originally the visor of a genuine Royal Enfield helmet repurposed as a display case. The rear cowl’s elimination enables accommodating an additional passenger.
While other manufacturers may have opted for a trendy monoshock setup, the Continental GT wisely sticks with its tried-and-true twin shock configuration. Equipped on a freshly minted subframe, Jay’s bespoke chromed steel exhaust system, his own unique design, cleverly separates the shocks, showcasing his attention to detail. The swingarm is another customizable component that expands the footprint of the bike. With the rear bodywork fully opened, all the Enfield’s electrical systems are repositioned to reside securely behind the fairing. The handlebars and footpegs are knurled aluminium gadgets Jay turned on his lathe and clear air flows into the engine through a Okay&N filter. Here’s an improved version: The outcome is a rugged, no-frills machine designed to excel on a racing track rather than navigating the bustling streets of India.
As a nod to the substantial amount of metalwork involved, Jay dubbed his latest Continental GT the ‘Metallic Jacket’. The construction project required four months to complete, with its outcome unlikely to resonate universally. No matter what anybody thinks we’re actually eager to see extra trendy cafe racers like this rolling out of J&D Customized Co.
J&D CUSTOM CO.
Images by Fanil Pandya & Harshil Majmudar
