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Thread: 1984 Katana 7/11

  1. #391
    Join Date
    Jul 2013
    Location
    New Zealand
    Posts
    163

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    Looking great, i am always amazed what you are able to achieve with basic tools. No laser cutting, lathes and mills.
    Well done, the plates look excellent.
    Current Bikes.... 81,1230Kat, 86,GSXR1100, 86,RG500,
    The 80`s - Back in the days when men looked like women, women dressed like whores and the music F@#KING ROCKED!

  2. #392
    Join Date
    May 2005
    Location
    Keperra, Queensland, Australia
    Posts
    12,682

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    Cheers mate! Although there will be a mill involved soon... a mate has offered the use of the milling attachment on his lathe to use to recess the bolt holes in the anti-dive plates so they're a bit neater.

    Gotta say I like your signature! Got a pic of that Kat?

  3. #393
    Join Date
    May 2005
    Location
    Keperra, Queensland, Australia
    Posts
    12,682

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    I had a trip down to a mate's place during the week where we got some milling done, and then during the weekend I finished them up with a little more filing and sanding then a run on the cutting and buffing wheels.





    He also kindly provided an offcut of pig skin gasket material which I cut two gaskets from.



    Then I applied some blue loctite and bolted them in place followed up by a quick once over with the Mothers polish.







    I got the right preload adjuster cleaned up so it moves properly now into all four positions and got everything ready to assemble.





    Then I realised... can't use a big socket to drift the fork seal into place because the damper rod and stanchion go in first.

    What trick do you guys use to get these in safely? That's the only thing holding me up now...


  4. #394
    Join Date
    May 2005
    Location
    Keperra, Queensland, Australia
    Posts
    12,682

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    I found a piece of PVC pipe the exact right size for the fork seals and the copper washers for the damper rod bolts showed up during the week so I was able to finish the forks off yesterday.

    Pretty happy with the end result, nice and clean and tidy.



    And I remembered to the do the fork caps as well.



    I spent a while on the shock mount bushes on the swingarm but no matter what I did they would'nt budge at all.

    I soaked them in Inox then found a pretty perfectly sized socket with a large one for the back side.

    I tried both the bench vise and bolt through the middle methods, and all I managed to do was break the bolt and bend the bench vise arm with the breaker bar.

    As the bushes are rubber I wasn't game to try heat, so I think my only choice at this point is to cut the rubber to get the inner metal ring out, then carefully cut the outer metal ring to allow it to shrink a bit and release. Not pretty but I'm out of ideas on any other way at the moment.

    Once I get those sorted I want to assemble the basic roller again and use a pro-tip I got and use a spirit level to confirm my frame/forks/swingarm are all pretty straight.

  5. #395
    Join Date
    May 2005
    Location
    Keperra, Queensland, Australia
    Posts
    12,682

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    I had three things I wanted to achieve yesterday... get some parts so I can make a press for the shocky bushes in the swingarm, get the basic roller put together so I can do the quick and dirty check for straightness, and clean the wheels up so I can see if I need to paint them or not.

    I assembled the basic roller... if only that frame was powder coated and this was final assembly...

    Made sure it was on a level part of the shed floor then started moving the spirit level around the frame, and all good. I didn't notice a difference at any point from front to back or across the swingarm.

    I also checked the front and rear tyres vertically and they were good too, so I'm pretty happy I don't need to worry any more about that.

    I know it doesn't check front to rear alignment and while I didn't string line it, line of sight definitely shows the front/rear tyres aligned which is enough for me to proceed.







    Then I managed to get some steel, threaded rod, etc. to make the press, but got back too late to break out the angle grinder to start cutting, but at least I have the parts and a plan now.

    I still did manage to get the wheels out and give them a good soak in degreaser and a rub down with a scrubbing brush. They're not perfect but they'll work as is for what I want. At least if I change my mind down the track they can pretty easily be removed and painted later.


  6. #396
    Join Date
    May 2005
    Location
    Keperra, Queensland, Australia
    Posts
    12,682

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    After losing last Sunday to work, I finally got to finish my press off to a useable state yesterday.

    It's not the prettiest thing in the world but it seems to be useable and functional which is all that matters.

    The only suitable steel I could find was two U sections welded together back to back to form a H section, so I had to tack some plates on to give a flat surface to press on.

    I tacked some nuts on the back of the plates so I could bolt down the sockets to keep them in place also.

    The only suitable thing I could find handy was some timber to somewhat clamp the jack in place, just mainly to stop it moving around.

    Hopefully I can use this as somewhat of a metal brake for next time I need to bend some sheet steel or aluminium too.



    I still had to apply heat to the swingarm but getting the bushings out wasn't that big a deal once I was able to use the press.



    Getting the new ones in was even easier after 30 minutes in the freezer and then using the press again.


  7. #397
    Join Date
    May 2005
    Location
    Keperra, Queensland, Australia
    Posts
    12,682

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    Ducked over to see a man about a horse last night... came back with starter clutch, stator, rotor, etc.


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