Custom Fighter: Honda Hornet 600 Custom

FVT 12: Twin-Seat CB600F from Francis Von Tuto…  

In 1998, Honda launched their CBR600F-powered naked bike, the Hornet 600. Built in Italy, the bike featured a re-tuned version of the last-gen CBR supersport engine, a steel frame, and upright ergonomics — something of a factory streetfighter. While the bike was slow to catch on at first, it quickly become a bestseller in Europe and came to North America as the Honda 599.

The Hornet 600 boasted its own race series, which supported the British GP, and has been called one of the most versatile bikes of all time, appealing to veteran and beginner riders alike.

“More experienced riders loved the free-revving motor, which was simple to tune and benefited from an aftermarket exhaust. Despite its simplicity the chassis ran circles around the Bandit, its biggest competition at the time.” –MCN

In recent years, Hornet has also become a popular donor for custom bike builders. So we were very excited to see what our friend Francesco Tutino of Italy’s Francis Von Tuto Moto Works — one of our favorite builders on both a personal and professional level — would do with a first-generation Hornet build.

This one came his way from World Superbike team manager Roberto Catani, who was looking for someone to take over the build for his client, Silvano. Says Francesco:

“What was clear from the beginning was that the seat should still be comfortable for the pillion and that we couldn’t change the fuel tank, so there was a bit of challenge in this build and that kept me positive and willing to deliver the best work possible.”

Francesco details all of the modifications below. Particularly trick is the one-off rear subframe whose seat base, side covers, and rear loop mate with the tank via a single hidden M6 hex nut turned on the lathe. The dual-density saddle comes from BF Tappezzerie of Francesco’s native Florence, and a double-braced plate holder was fabricated for the swingarm.

Up front, there’s a TIG-welded aluminum mount for the LED headlight and laser-cut aluminum flyscreen, which protects a low-profile Motogadget Motoscope Pro. The bike is now running a side-mounted exhaust with Francesco’s twin slash-cut custom silencers, matched with BMC pod filters and a Dynojet stage 3 tuning kit courtesy of Faster96. Barring paint and upholstery, all the work was done in-house. Even the mudguard is a one-off:

“Full aluminium, 4 pieces, rolled, wheeled and TIG-welded at FVT’s workshop.”

The end product looks like a “2024” Honda Hornet — a bike out of an alternate reality where Honda kept the beloved Honda alive well into the 2020s with more of a retro / classic style. It looks amazing, and Francesco says it’s a hoot to ride, too:

“What I thought at the first test ride was: noooice, haven’t ridden a Hornet for so long! It’s basically still a Hornet but feels narrower, and definitely fun! Sounds pretty gnarly too.”

Below, we talk to Francesco for the full nitty-gritty details about the build, and credit goes to Rafael Montañes Ruiz for the absolutely gorgeous photos which took several early morning efforts — and some trick piloting — to capture. Worth it!

Hornet 600 Custom: Builder Interview

• What’s the make, model, and year of the bike?

It’s a 2006 Honda CB600F also known as the Hornet. This is the last of the steel frame model before they switched to an aluminium chassis, ’07 CBR600RR engine, and a totally new look.

• Why was this bike built?

A good friend of mine, Roberto Catani (WSBK team manager and awesome motorbike tech), called me to ask if I wanted to build one of his customer bikes since he didn’t have the time to complete the project anymore.

The bike had sat totally stripped for two years in his workshop (it was a rolling chassis when I picked it up), so time to start the mods was more than due. I met with Silvano the owner, found an agreement, and took the bike with me.

• What was the design concept and what influenced the build?

What was clear from the beginning was that the seat should still be comfortable for the pillion and that we couldn’t change the fuel tank, so there was a bit of challenge in this build and that kept me positive and willing to deliver the best work possible.

For the livery we used the same colours as Silvano’s Jeep Cherokee Trialway, same per the upholstery, to save us maintenance problems we didn’t use leather for the seat but we used a similar vinyl and red trim.

• What custom work was done to the bike?

For starters, everything plastic was immediately ditched.

Then I found the areas I had to work on: The back part of the chassis had to be slightly shortened and curved downwards to give the bike the right stance but I’ve kept most of those ugly boxy tubes to have a strong structure since it’s a twin seater, then made the shape of the tail bending some round steel tube and welding it to the main frame.

Of course I didn’t wanted to show any of the original framework so I’ve made two side covers which also hide the wiring, battery, and overflow reservoir, and the rec/reg has been moved down between the frame and swingarm.

The seat base is made using multiple layers of fiberglass and it mates the tank, side covers, and back loop surfaces very closely. You can remove it by unscrewing a single M6 hex nut purposely made at the lathe, which hides in the frame just above the rear tyre.

I’ve calculated the suspension travel and there is all the clearance needed between the chassis and the tire, but I thought that with the bolt hidden it would look a neater job. The seat, from the two density foam to the cover, was performed by my only choice BF Tappezzerie in Florence.

Engine is standard but with the airbox gone and those beautiful BMC pod filters, I had to install a Dynojet stage 3 tuning kit (both from Faster96).

One of the customer’s critiques on the Hornet was the smell of exhaust fumes on the clothes even after a short ride due to the undertail exhaust, so the problem was solved by moving it to the side. The headers are stock with the last part modified to allow my side-mounted twin slash-cut custom mufflers.

With the back end streamlined from its original proportions, the front needed the same treatment, so the dash was replaced with a superb Motogadget Motoscope Pro, mounted on a custom plate and protected by a mini windshield both in laser-cut aluminium.

The owner provided an LED headlight and I built an aluminium custom stay for it, completely handmade, bent, milled, turned and TIG-welded in-house.

Last but not least is the mudguard. Full aluminium, 4 pieces, rolled, wheeled and TIG-welded at FVT’s workshop.

All the lighting is LED. The indicators are the super tiny 3 into 1 Highsider Proton at the back, and the front radiator is mounted with an ally laser-cut plate and the same Protons but in the simple indicator version.

With a short tail, first of all you need a rear mudguard (and what a no-brainer off ebay). Secondly there is no chance to fit the numberplate unless illegally angled or dangerously close to the wheel…better to build a new NP holder and double brace it onto the swingarm! So with a couple of CNC milled parts and some more laser-cut plates I’ve got the last component done and fitted.

• Does the bike have a nickname?

Apart from FVT12, which stands for Francis Von Tuto’s 12th build, Silvano the owner has an inscription dedicated to his family stitched on the seat, but this work of mine doesn’t have a proper name.

• Can you tell us what it’s like to ride?

What I thought at the first test ride was: noooice, haven’t ridden a Hornet for so long! It’s basically still a Hornet but feels narrower, and definitely fun! Sounds pretty gnarly too.

• Was there anything done during this build that you are particularly proud of?

Well at the beginning this project wasn’t really my cup of tea and I had to bring a few ideas and sketches to the table before finding the right direction, and the result is actually very satisfying.

ALSO, apart from paint and upholstery, all the design and mods were done in-house, which is what I love about building bikes… If I could I’d do the whole thing, but a wise man told me that you can’t do everything yourself and I think he’s right.

I wish to thank my good Andrea Gori for the laser cut and CNC parts.

Follow the Builder

Website: www.francisvontuto.com
Instagram: @francis_von_tuto
Facebook: Francis Von Tuto
BMC / Dynojet Distributor: Faster96
Saddle: BF Tappezzerie
Photo credit: Rafael Montañes Ruiz

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