When we hear the term ?sand cast,? we think of very early Honda CB750s and their famous sandpaper-rough engine cases. But it?s not a technique restricted to big factories or large-scale production.
This elegant, stripped down Triumph 6T Thunderbird is a showcase for small-scale casting, and earned its builder an invitation to the Biltwell People?s Champ competition?which is part of the Born Free show in the USA.

But this Thunderbird wasn?t built in a foundry in the Midwest: it was put together in the suburban back garden of a small terraced house in the middle of England. The builder is the remarkably talented Robbie Palmer, who created the lovely Triumph Daytona bobber we featured a couple of months ago.
He?s based in Northampton, a struggling former industrial town which is an unlikely location for a top-flight customizer. But despite the unpromising environs, Robbie has turned out a stellar build. Even more surprisingly, it?s only his second ?full? custom.
?I made a lot of sand cast parts, all sculpted from clay and cast in my back garden workshop,? he says. ?That included the fuel tank, the primary cover, oil tank, fender and seat pan.? He also cast the headlight, throttle, air filter, kicker pedal and footpegs.
?My back garden shed is right in the centre of town. It’s overlooked by other houses and my neighbours were probably surprised to see sand casting happening in such a tiny space. The sound of the furnace firing up caused lots of curtain twitching, t...