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1981 GSX1100 Katana Based Project

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    #166
    Screen number 3 was salvageable and is now the Number One Banana. It turned out heavier than I would have liked, without a vacuum unit I had to apply the resin "Old School" with a brush and resulted in using more resin than optimal and made it heavier.

    Carbon screen final version 153 grams including molding trim.


    url=https://flic.kr/p/2p8kLmq][/url]DW screen 3 by Max Mutarn, on Flickr


    Carbon screen bracket at 134 grams, again I used to much resin and it is pretty heavy.


    DW screen bracket 1 by Max Mutarn, on Flickr


    Gave the bracket some support at the base by rolling carbon around a paper tube. After the carbon had cured removed the paper tube.

    DW screen bracket 2 by Max Mutarn, on Flickr
    Last edited by Shin-Ken 1074; 10-10-2023, 05:35 AM.
    Badgezz, we don need noh stinkin' badgezz!
    Shin-Ken 1074
    1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
    1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
    • Likes 2

    Comment

      #167
      Finished screen in position on the cowl. Screen and bracket weigh 287 grams, 187 grams lighter than OEM screen/bracket but it was a lot of work for that 187 grams.
      ​

      DW screen 5 by Max Mutarn, on Flickr

      DW screen 4 by Max Mutarn, on Flickr
      Badgezz, we don need noh stinkin' badgezz!
      Shin-Ken 1074
      1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
      1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.
      • Likes 1

      Comment

        #168
        So the wind screen is opaque?
        1982 GS1100E V&H "SS" exhaust, APE pods, 1150 oil cooler, 140 speedo, 99.3 rear wheel HP, black engine, '83 red

        2016 XL883L sigpic Two-tone blue and white. Almost 42 hp! Status: destroyed, now owned by the insurance company. The hole in my memory starts an hour before the accident and ends 24 hours after.

        Comment

          #169
          Originally posted by Rob S. View Post
          So the wind screen is opaque?
          Yes, the Kat screen function is to direct airflow up and over the rider at high speed and isn't designed to see through it so being opaque is no problem.
          Badgezz, we don need noh stinkin' badgezz!
          Shin-Ken 1074
          1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
          1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

          Comment

            #170
            Okay, just don't take it too far. No carbon fiber helmet visors!
            1982 GS1100E V&H "SS" exhaust, APE pods, 1150 oil cooler, 140 speedo, 99.3 rear wheel HP, black engine, '83 red

            2016 XL883L sigpic Two-tone blue and white. Almost 42 hp! Status: destroyed, now owned by the insurance company. The hole in my memory starts an hour before the accident and ends 24 hours after.
            • Likes 1

            Comment

              #171
              Originally posted by Rob S. View Post
              Okay, just don't take it too far. No carbon fiber helmet visors!
              How did you know that was the next carbon part for the project? A 40mm holesaw and two holes in the visor?
              Badgezz, we don need noh stinkin' badgezz!
              Shin-Ken 1074
              1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
              1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

              Comment

                #172
                Not happy with the screen weight, may have to revisit that?
                Badgezz, we don need noh stinkin' badgezz!
                Shin-Ken 1074
                1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                Comment

                  #173
                  The Kat has rubber fins mounted on the lower side of the cowl and do two jobs, direct airflow to the engine and to look cool. Problem is they are a bit chunky and could do with a diet. No curves or tight corners so making the fins in carbon fibre was no drama. Force on the fins is minimal so I went with the lightest bolt option I could think of, nylon. Reduced the weight of the nylon bolts by drilling the shank and countersink drilling the bolt head.


                  These are the OEM rubber fins and bolts/nuts.

                  OEM cowl fins by Max Mutarn, on Flickr


                  Nylon bolts before drilling.

                  Nlyon fin bolts before by Max Mutarn, on Flickr


                  nylon fin bolts 2 by Max Mutarn, on Flickr



                  Nylon fin bolts after 1 by Max Mutarn, on Flickr






                  Carbon fins and nylon bolts.


                  DW carbon fins and nylon bolts by Max Mutarn, on Flickr
                  Last edited by Shin-Ken 1074; 10-11-2023, 04:16 PM.
                  Badgezz, we don need noh stinkin' badgezz!
                  Shin-Ken 1074
                  1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                  1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                  Comment

                    #174
                    Made one other part in carbon, the starter motor cover plate. The shape of the cover is one that a vacuum unit would have made without a problem. Making it by hand got pretty ugly and took a few tries to get it right. The curves just didn't want to release from the OEM metal cover no matter how much release agent I used.

                    Badgezz, we don need noh stinkin' badgezz!
                    Shin-Ken 1074
                    1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                    1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                    Comment

                      #175
                      This is one of the most interesting threads I've seen on this forum in a long time. Following with interest.
                      Charles
                      --
                      1979 Suzuki GS850G

                      Read BassCliff's GSR Greeting and Mega-Welcome!

                      Comment

                        #176
                        Originally posted by eil View Post
                        This is one of the most interesting threads I've seen on this forum in a long time. Following with interest.
                        Hi Eil, thank you.
                        Badgezz, we don need noh stinkin' badgezz!
                        Shin-Ken 1074
                        1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                        1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                        Comment

                          #177
                          Rear caliper bracket paint has cured after the modification to adapt the K5 rear brake caliper to the 1981 Suzi swing-arm. Swing arm, caliper and rear wheel will be installed next week.

                          The stock K5 mount.


                          OEM K5 caliper bracket by Max Mutarn, on Flickr


                          K5 mount mod.

                          DW caliper bracket com1 by Max Mutarn, on Flickr


                          DW caliper bracket com2 by Max Mutarn, on Flickr


                          K5 caliper and DW bracket by Max Mutarn, on Flickr
                          Last edited by Shin-Ken 1074; 10-11-2023, 06:29 PM.
                          Badgezz, we don need noh stinkin' badgezz!
                          Shin-Ken 1074
                          1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                          1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                          Comment

                            #178
                            The exhaust system for the DW had steel header flanges fitted when I bought it so they had to go. Didn't want to damage the headers using an angle grinder with a cutting disc so used a hacksaw blade and slowly worked through each flange. No damage done.

                            Four of these and eight steel bolts, 840 grams total.

                            Shouldn't need to many guesses as to what will replace these boat anchors.

                            Steel header flange 1 by Max Mutarn, on Flickr


                            Steel header flange 2 by Max Mutarn, on Flickr



                            Steel header flange 3 by Max Mutarn, on Flickr
                            Badgezz, we don need noh stinkin' badgezz!
                            Shin-Ken 1074
                            1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                            1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                            Comment

                              #179
                              Full titanium exhaust, I presume?
                              1982 GS1100E V&H "SS" exhaust, APE pods, 1150 oil cooler, 140 speedo, 99.3 rear wheel HP, black engine, '83 red

                              2016 XL883L sigpic Two-tone blue and white. Almost 42 hp! Status: destroyed, now owned by the insurance company. The hole in my memory starts an hour before the accident and ends 24 hours after.

                              Comment

                                #180
                                Originally posted by Shin-Ken 1074 View Post
                                The exhaust system for the DW had steel header flanges fitted when I bought it so they had to go. Didn't want to damage the headers using an angle grinder with a cutting disc so used a hacksaw blade and slowly worked through each flange. No damage done.

                                Four of these and eight steel bolts, 840 grams total.
                                Technically, would the original weight be slightly more than the aforementioned 840 grams only since you are not measuring the removed materials from the saw? Maybe closer to 850 grams by my estimation?

                                Either way, I am fully invested in seeing the final product and thoughts after riding it. You are doing great work.

                                Comment

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