We’ve got ours keep an eye on Sean Skinner at MotoRelic for a while. The Virginia-based builder has a knack for creating orderliness the rest and customs, and know how to maintain that ‘factory’ vibe. But he just threw us a big ball with his latest project: a Schwinn-inspired classic. Yamaha XS650.
This disparity from the regular MotoRelic fare was conceived six years ago. Sean had the unusual idea of building a full-size replica of Schwinn’s famous 1968 Stingray Orange Krate helicopter. Bikepowered by a motorcycle engine.
“Put in the mix that I’ve never built a complete framework before — or so many other pieces on this build after that,” he told us. “I got a clean stock frame that I cut off the neck of, so I could keep the proper VIN. Then I fitted the lonely neck to my recently purchased bracket and started thinking about what I wanted it to look like. “
Sean’s challenge was to recreate the warping lines of Stingray’s tubular frame. First, he built the bottom ring of the frame, using an engine model to get the proportions right. He then used the PVC pipe to prototype the rest of the design, before shaping each steel pipe with a ring roller.
After all the tubes were in place and looked like the pictures Sean was working on, he went ahead and put in the final welds. From a distance, the chassis looks like a single structure, but the two tubes running along the bottom of the tank are actually separate pieces. They are there to add extra bracing and act as upper engine racks.
But that’s how much Sean got before the project stalled. “I tripped and the frame sat for four years in my basement,” he told us. “It was either lack of money for all the engine parts or lack of confidence in building the front end…probably both.”
“As time went on, I never forgot the construction; It’s not a top priority. Until one day I was surfing Marketplace and came across an XS650 that a good friend built. He is selling a bike with the perfect engine for my work.”
Sean doesn’t exaggerate when he says “perfect”. The XS650 Factory has been ‘staged’ by Hugh’s Hand Built – an extensive rebuilding process that changes the firing order from 360 to 277 degrees. It’s also fully polished with a ‘big fin’ cylinder, an electronic ignition and lots of new chrome parts.
With one main component sorted, the project is back up and running. The front end is next on Sean’s list – but first, he needs to sort out Schwinn’s signature large rear wheel, to get the height just right. A 21-inch rim attached to a stock XS650 hub with Buchanan spokes did the trick.
“Fixing the funny big wheels into the frame really allowed me to see my vision in real life,” he says. “It’s lovely.”
Sean knows exactly what ‘banana beam’ looks like — but implementing it will be difficult. So he scoured the internet and found a shop that builds them for Harleys. The scales were all wrong, but Sean managed to convince them to sell him a joystick and its ‘hats’, giving him a head start.
Using a 17” drum brake wheel he picked up from a friend during a swap meet, Sean started crunching the numbers to get the shape just right. With a rudimentary jig to stack all the pivot points, he put it all together — machined custom pads and decks as he went. An adjustable mountain bike shock has been added to add a little more compliance on the road.
The handlebars were created by attaching a brand new set of monkey hangers and welding them to the front end. Sean wanted to keep the cockpit as clean as possible, so he used an internal throttle and soldered the hand-made levers directly to the bars. Everything is connected with new cables from Venhill.
The foot controls are put together using an aftermarket set of latches, an old Harley mount, and a Magura switch for the rear brake.
Another challenge was finding a tank that would match the classic lines of the Stingray, but still hold at least two gallons. “While sitting in the store, I noticed an old Virago tank hanging on the wall,” Sean tells us. “I can see from the side that it has the same curved shape on the side of the tank.”
“I made a tunnel and platform for the new tank according to the frame. Once that was in place, I cut the Virago tank and found the shape I needed in two pieces. More sanding and testing fit than I’d like to admit, and I’ve fitted the tank parts in place. “
For the classic banana saddle, Sean built an aluminum saddle pan, then shaped it with sponge to complement the curves of the tank.
The original Schwinn Stingray used shocks at the bottom of the sissy bar to add some cushioning to the car — and Sean is adamant about recreating that. So he sourced some springs and bushings from McMaster-Carr, and machined all the parts to create a full-size version of the classic seat shock. The seat hinges on one axle are well hidden at the front.
The last thing Sean has a headache is the exhaust. After a few failed ideas, he decided to build a pair of curved tubes that could track the frame to blend into the overall design. There is a baffle welded to each pipe, to keep noise levels to a reasonable level.
The rest of the construction is completed with a series of thoughtfully handcrafted parts. The attention to detail is outstanding – and is visible even on functional components such as the fuel pipes and the rear tank holder.
The final color scheme was also the winner, and got the whole team to do it. Right A Way Powder in Middletown does the candy orange treatment on the frame, while DGM Chrome Plating in Philadelphia does all the chrome plating. Roxan at Range Needlework in Arizona repaired the chair, upholstering it in a gorgeous, retro-styled white glitter vinyl.
Danny Knight at Knights Kustoms in Winchester, Virginia shot a heavy peeling white paint on the tank. And John Ralph at Quail Run Signs created stencils to paint the Yamaha logo in the Schwinn style.
With everything prepared, there was only one thing left to do: ride it. Sean said: “It took about five kicks for her to go on. “Blam it on dry carbs, no batteries, stage fright or whatever — but it kicked in and it sounded great.”
“It’s been laughs for miles about this. It handles well and rides beautifully. ”
“You have to look at this bike and smile at the fact that it was built from the inspirational dreams of the Schwinn Stingray Orange Krate. A delightfully whimsical construction is art in motion and nothing else. A childhood memory of shabby bikes with square cuts that aren’t handled well, but are there for fun. “
Amen for that.
MotoRelic | Instagram | Image of Jonathan Thorpe
