Breathing New Life into a 1984 Honda XL250 with Custom 3D Printed Carburetor Caps
At Elliott Motorcycles, we pride ourselves on turning impossible parts into precision-engineered realities. No job is too large or too small. Recently, a Sydney motorcycle workshop restoring a 1984 Honda XL250 approached us after an exhaustive search for replacement carburetor end caps had come up empty.
The original caps had cracked over time, leading to air leaks that rendered the bike unrideable. Genuine replacements were practically unobtainable—either unavailable, prohibitively expensive, or in poor condition.
Our Solution: Reverse Engineering Meets Advanced Manufacturing
Working closely with the customer, we quickly reverse engineered the original caps using precision CAD tools. Within just a few days, we delivered a set of brand-new carburetor caps that not only matched the original dimensions and appearance but performed like factory-new components.
The parts were manufactured using one of our Markforged industrial 3D printers, utilizing Onyx FR, a flame-retardant, micro carbon fiber-filled nylon. This advanced material is engineered for accuracy, durability, and a flawless surface finish—ideal for components exposed to engine bay conditions. For applications demanding additional strength, Onyx FR can also be reinforced with Continuous Fiber, delivering performance comparable to aluminum.
Perfect Fit, Instant Results
The new caps bolted on effortlessly and delivered a flawless seal. The technician reported that the bike has since logged many hours of smooth operation, with the replacement parts maintaining both their appearance and performance from day one.
Why This Matters
In the past, a small but essential part like this could leave a project stalled for months, or even permanently. With our in-house CAD modeling, 3D scanning, and additive manufacturing capabilities, we can now replicate and manufacture components quickly in a wide range of materials—from high-strength composites to stainless steel.
This project is a textbook example of how Elliott Motorcycles offers simple, fast, and elegant engineering solutions for hard-to-find parts. Whether it’s a vintage restoration or a custom build, we help keep motorcycles on the road and out of the parts-bin purgatory.
