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A Perfectionist’s FXR: Sam Smith’s Garage-Built Ripper

A Perfectionist’s FXR: Sam Smith’s Garage-Built Ripper

Some builds come together fast. Others take years and a few complete tear-downs. For Sam Smith, the road to the FXR of his dreams started in his dad’s garage and ended in his own—with a whole lot of late nights, busted knuckles, and second guesses along the way.

This one’s a rider’s bike, built by a rider, for himself.

From BMX to FXR

Sam, 35, built his FXR out of his home garage, he grew up wrenching on BMX bikes, then cars, eventually ending up where it always seems to lead for people like us: motorcycles. His dad’s FXR was the gateway drug and before Harley's it was Triumph choppers and metric bikes. “He got me into working with tools,” Sam says. “The FXR connection started with his Harley, but once I discovered the culture behind them, I was hooked.”

That original inspiration shows up in the current build’s paint—a nod to his dad’s old silver and black FXR shown above.

Sam's FXR In It's Original Form:

What started as a 1991 FXR has been completely rebuilt. Twice. “I’m a bit of a perfectionist,” Sam admits. “There was some stuff I wasn’t happy with on the first go, so I tore it back down and fixed it all.”

The Rebuild

Built solely by Sam, the bike illustrates his technical craftsmanship. "For the most part I prefer it this way as I get to just tick a long at my own pace", said Sam. An S&S V111 engine paired with a Mikuni HSR45 carb and Baker DD6 gearbox is the heart of Sam's bike. The suspension is managed by Racetech parts and Öhlins shocks, while a Metmachex swingarm and R1 caliper offer unique style without detracting from the bike's vintage feel. Modern performance and style are brought about by Thunderstar wheels and a Motogadget M-unit. The entire wiring system was made up from scratch—something Sam takes pride in.

Built To Ride

Sam’s goal wasn’t to win trophies—it was to build something reliable, responsive, and road-ready. “I wanted a good, strong bike I could count on,” he says. “It took a while to get to the reliable part, but I think we’re there now.”

The V111 powerplant and upgraded chassis components give this FXR more than enough punch, while still feeling refined. “The FXR has always felt like a tightly wound spring. It’s powerful now, but smooth. Way more fun than my Dyna.”

Spec Sheet

Powertrain

  • S&S V111 engine
  • Mikuni HSR45 carb
  • SDC air cleaner
  • Baker DD6 transmission
  • Barnett Scorpion clutch
  • Thunderheader with Ramjet bracket

Chassis & Suspension

  • Ohlins rear shocks
  • Racetech forks
  • SDC fork brace
  • Pro1 top clamps
  • Metmachex swingarm with R1 caliper (UK-made, custom, clean)

Wheels & Brakes

  • Thunderstar wheels
  • Thunderstar rotors

Cockpit & Controls

  • Powerplant U bend bars, gas cap, and coil cage
  • Motogadget M-Unit and Motoscope wired to a custom harness
  • Every bolt replaced or upgraded—many with titanium or stainless

Fab & Wiring

Aside from welding in a new fork stop and cleaning up the VIN plate area to tuck it under the seat, most of the custom work was electrical. “I actually enjoy wiring,” Sam says. “It’s the part people usually hate, but it comes easy to me.”The entire wiring harness is built from scratch and is routed to look clean without sacrificing function.

Community Over Everything

If you ask Sam what the best part of the process was, it isn’t a specific part or mod—it’s the people. “I’ve met friends all over the world through the FXR community. That’s what really sticks.” But that first ride after the second rebuild? That’s up there too. “It reminded me exactly why I love these bikes. You’re not sitting in it, you’re sitting on it. It’s raw, it’s alive.”

Give Sam a follow on Instagram at @samfour_

4th Jun 2025 Steve B.

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